Acoustic article, decorative element, and systems comprising same

ABSTRACT

Acoustic articles, decorative elements, and system comprising the same can include a decorative element having a first side and an opposing second side, and an acoustic article disposed on the opposing second side of the decorative element. The acoustic article can include an entangled fiber structure. The acoustic article can have a thickness of at least 0.4 mm, and can compress less than 25% of the thickness thereof when subjected to a pressure of 2 lbf/in 2 .

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of PCT Application No.PCT/US22/51221, filed Nov. 19, 2022, which claims the benefit of therespective filing dates of U.S. Provisional Patent Application Nos.63/357,863, filed Jul. 1, 2022, 63/295,163, filed Dec. 30, 2021, and63/283,955, filed Nov. 29, 2021, the entirety of each of which is herebyincorporated by reference herein for all purposes.

FIELD

This application relates generally to acoustic articles and decorativeunits comprising the same.

BACKGROUND

Decorative elements can form aesthetic surfaces for various environmentsor can be applied as skins to cover various sub structures to achieve adesired aesthetic and/or functional purpose. Such decorative elementsare often used in residential and commercial spaces.

Acoustics in interior spaces are a concern for building manufacturers aswell as the users of the interior spaces. For example, it can bedesirable to minimize sound between adjacent rooms that share a surfacestructure (e.g., wall/floor/ceiling). Similarly, it can be desirable tominimize sound transferred between adjacent stories of a buildingthrough the shared surface structures (e.g., wall/floor/ceiling).

SUMMARY

Disclosed herein, in one aspect, is a system comprising a decorativeelement having a first side and an opposing second side. The decorativeelement has a first surface on the first side and a second surface onthe opposing second side. An acoustic article is disposed on theopposing second side of the decorative element. The acoustic articlecomprises a resiliently compressible material; has a thickness of atleast 0.4 mm; and is compressible by less than 25% of the thickness whensubjected to a pressure of 2 lbf/in². A stiffening structure ispositioned between the decorative element and the acoustic article.

Also disclosed herein, in various aspects, is a decorative unitcomprising a decorative element having a first side and an opposingsecond side. The decorative element has a first surface on the firstside and a second surface on the opposing second side. An acousticarticle is disposed on the opposing second side of the decorativeelement. The acoustic article comprises a resiliently compressiblematerial; has a thickness of at least 0.4 mm; and is compressible byless than 25% of the thickness when subjected to a pressure of 2lbf/in². A stiffening structure is positioned between the decorativeelement and the acoustic article.

Also disclosed herein, in various aspects, is subsurface articlecomprising an acoustic article comprising a resiliently compressiblematerial. The acoustic article has a first side defining a first surfaceand an opposing second side defining a second surface. The acousticarticle comprises a resiliently compressible material; has a thicknessof at least 0.4 mm; and is compressible by less than 25% of thethickness when subjected to a pressure of 2 lbf/in². The subsurfacearticle further comprises a stiffening structure is positioned on thefirst side of and, optionally, disposed on the first surface of theacoustic article. When the subsurface article is disposed below adecorative element, the stiffening structure is positioned between thedecorative element and the acoustic article.

Methods of using the systems, decorative units, and subsurface articlesare also disclosed.

Additional advantages of the invention will be set forth in part in thedescription that follows, and in part will be obvious from thedescription, or may be learned by practice of the invention. Theadvantages of the invention will be realized and attained by means ofthe elements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the preferred embodiments of the inventionwill become more apparent in the detailed description in which referenceis made to the appended drawings wherein:

FIG. 1 is a schematic diagram of a system comprising a decorativeelement and an acoustic article as disclosed herein.

FIG. 2 is a schematic diagram of a system comprising an acoustic articlehaving a plurality of layers.

FIG. 3 is a schematic diagram of a system comprising a barrier and aleveling material thereon.

FIG. 4 is a schematic diagram of a decorative unit comprising adecorative element and an acoustic article as disclosed herein.

FIG. 5 illustrates an exemplary installation of the system on asubfloor.

FIG. 6 illustrates an exemplary installation of the system on asubfloor.

FIG. 7 illustrates an exemplary installation of the system comprising aleveling material on a subfloor.

FIGS. 8 and 9 illustrate acoustic properties of an exemplary systemdisclosed herein as compared to other conventional decorative elementsystems.

FIG. 10 illustrates an exemplary decorative element comprising adecorative portion and a substrate.

FIG. 11 is a schematic diagram of a diagram of a system comprising adecorative element, an acoustic article, and a stiffening structurebetween the decorative element and the acoustic article, as disclosedherein.

FIG. 12 is a schematic diagram of the system of FIG. 11 , wherein thestiffening structure comprises a plurality of layers.

FIG. 13 shows a perspective view of an exemplary test apparatus forperforming the test method ASTM D1388-18.

FIG. 14 is a perspective view of a material being tested on the testapparatus of FIG. 13 .

DETAILED DESCRIPTION

The disclosed system and method may be understood more readily byreference to the following detailed description of particularembodiments and the examples included therein and to the Figures andtheir previous and following description.

It is to be understood that the terminology used herein is for thepurpose of describing particular embodiments only and is not intended tolimit the scope of the present invention which will be limited only bythe appended claims.

It must be noted that as used herein and in the appended claims, thesingular forms “a,” “an,” and “the” include plural references unless thecontext clearly dictates otherwise. Thus, for example, reference to “alayer” includes one or more of such layers, and so forth.

“Optional” or “optionally” means that the subsequently described event,circumstance, or material may or may not occur or be present, and thatthe description includes instances where the event, circumstance, ormaterial occurs or is present and instances where it does not occur oris not present.

Ranges may be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, also specifically contemplated and considered disclosed isthe range from the one particular value and/or to the other particularvalue unless the context specifically indicates otherwise. Similarly,when values are expressed as approximations, by use of the antecedent“about,” it will be understood that the particular value forms another,specifically contemplated embodiment that should be considered disclosedunless the context specifically indicates otherwise. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint unless the context specifically indicates otherwise. Finally,it should be understood that all of the individual values and sub-rangesof values contained within an explicitly disclosed range are alsospecifically contemplated and should be considered disclosed unless thecontext specifically indicates otherwise. The foregoing appliesregardless of whether in particular cases some or all of theseembodiments are explicitly disclosed.

Optionally, in some aspects, when values are approximated by use of theantecedents “about,” “substantially,” or “generally,” it is contemplatedthat values within up to 15%, up to 10%, up to 5%, or up to 1% (above orbelow) of the particularly stated value or characteristic can beincluded within the scope of those aspects.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meanings as commonly understood by one of skill in the artto which the disclosed apparatus, system, and method belong. Althoughany apparatus, systems, and methods and materials similar or equivalentto those described herein can be used in the practice or testing of thepresent apparatus, system, and method, the particularly useful methods,devices, systems, and materials are as described.

Throughout the description and claims of this specification, the word“comprise” and variations of the word, such as “comprising” and“comprises,” means “including but not limited to,” and is not intendedto exclude, for example, other additives, components, integers or steps.In particular, in methods stated as comprising one or more steps oroperations it is specifically contemplated that each step comprises whatis listed (unless that step includes a limiting term such as “consistingof”), meaning that each step is not intended to exclude, for example,other additives, components, integers or steps that are not listed inthe step.

Disclosed herein are acoustic articles, decorative elements, and systemscomprising the same. The decorative elements can form both functionaland aesthetic surfaces for various environments. For example, thedecorative elements can form a floor, wall, or ceiling surface. Theacoustic article along with the decorative element can have additionaladvantages such as, but not limited to, acoustic advantages, underfootcomfort advantages, etc., as will be discussed in greater detail below.

Referring to FIG. 1 , an exemplary system 10 comprises a decorativeelement 12 having a first side 14 and an opposing second side 16. Thedecorative element has a first surface 15 on the first side 14 and asecond surface 17 on the opposing second side 16. An acoustic article 20is configured to be disposed on the opposing second side 16 of thedecorative element 12. In further aspects, the acoustic article 20 isdisposed on the opposing second side 16 of the decorative element 12. Insome optional aspects, the acoustic article 20 can be coupled to thesecond surface 17 of the decorative element 12. In other optionalaspects, the decorative element 12 can be positioned against, but notcoupled to the acoustic article. In other aspects, and as furtherdescribed herein, one or more layers or structures can be disposedbetween the decorative element 12 and the acoustic article 20. Theacoustic article 20 has a thickness 22 between a first side 24 and anopposed second side 26. In some aspects, the acoustic article 20 can beintegrally attached to the decorative element 12, whereas in otheraspects, the decorative element 12 can be disposed on top of an alreadyinstalled acoustic article 20. In yet other aspects, the acousticarticle 20 may be embedded within the decorative element 12.

As used herein, “decorative element,” “hard surface flooring material,”“hard surface floor panel,” and “floor panel” are used interchangeablyand should be understood to have the same scope and meaning. Forexample, the term “decorative element” should be understood to mean ahard surface flooring material.

As used herein, “acoustic article” and “base pad” are usedinterchangeably and should be understood to have the same scope andmeaning. For example, the term “acoustic article” should be understoodto mean a base pad.

As used herein, “decorative unit” and “flooring element” are usedinterchangeably and should be understood to have the same scope andmeaning. For example, the term “decorative unit” should be understood tomean a flooring element.

As used herein, “entangled fiber structure” should be understood to bedefined as a woven material, a non-woven material, and a combinationthereof.

In one example, the system 10 disclosed herein can be a hard surfacefloor panel 12 configured to be connected to another hard surface floorpanel 12 (hereinafter “floor panel”). As such, the floor panel 12 can beconfigured to be connectable to or interlocked with the floor panel 12of another system. For example, floor panel 12 can have tongue andgroove connections. The tongue of one floor panel 12 can be connected toa groove on another floor panel 12.

The base pad 20 can comprise a resiliently compressible material.Optionally, the resiliently compressible material can comprise, anentangled fiber structure (i.e., woven material, a non-woven material,or a combination thereof). In other aspects, the base pad 20 cancomprise any suitable material that provides the desired materialproperties. For example, the base pad 20 can comprise a foam, rubber, orcomposite. In some aspects, resiliently compressible material cancomprise, or be, cork. In exemplary aspects, the base pad 20 has athickness 22 that can be from about 0.4 mm to about 25 mm. Further, thebase pad 20 can be configured to compress by less than 25% of thethickness 22 when subjected to a pressure of 2 lbf/in² (pounds-force persquare inch).

In exemplary aspects, the thickness 22 can be about or at least 0.4 mm,about or at least 0.5 mm, about or at least 0.7 mm, about or at least 1mm, about or at least 1.5 mm, about or at least 2.5 mm, about or atleast 5.0 mm, about or at least 7.5 mm, about or at least 10 mm, aboutor at least 15 mm, about or at least 20 mm, about or at least 25 mm, orfrom about 0.4 mm to about 25 mm, or from about 0.4 mm to about 7 mm, orfrom about 0.5 mm to about 25 mm, or from about 0.5 mm to about 7 mm, orfrom about 0.7 mm to about 25 mm, or from about 1.0 mm to about 10 mm,or from about 1.6 to about 5 mm. In some embodiments, the thickness canbe from about 3 mm to about 4.5 mm, or about 3.75 mm.

It is contemplated that the base pad 20 can have a thickness tolerancethat corresponds to a deviation in thickness that does not inhibit useof the base pad 20 with the floor panel 12. For example, a variation inthickness between two adjacent pads at opposite ends of the thicknesstolerance can permit respective floor panels 12 to engage each other(e.g., via tongue and groove or other locking system). It was discoveredthat the base pad 20 disclosed herein can have an exceptionally highthickness tolerance without inhibiting coupling between adjacent floorpanels 12 or without significantly compromising the locking strength orintegrity between the respective floor panels 12. This discovery was asurprising and unexpected result. For example, the compressibility ofthe base pad 20 permits alignment and coupling of the adjacent floorpanels 12. It is further contemplated that the coupling between coupledfloor panels 12 can permit flexing to accommodate the compressibility ofthe base pad 20. In some aspects, the base pad 20 can have a thicknesstolerance of less than 1 mm, or less than 0.5 mm, or about 0.4 mm. Infurther aspects, the base pad can have a thickness tolerance of at least0.2 mm, or at least 0.3 mm, or at least 0.4 mm, or at least 0.5 mm, orat least 0.75 mm, or at least 1 mm, or more. In some optional aspects,the thickness tolerance of the base pad can be from about 0.3 to about 1mm. In some optional aspects, the thickness tolerance of the base padcan be from about 0.3 to about 0.5 mm. In some optional aspects, thethickness tolerance of the base pad can be from about 0.3 to about 4 mm.In some exemplary aspects, the base pad 20 can have a thickness of about3.75 mm+/−0.4 mm. That is, the base pad 20 can have a thickness of 3.35mm-4.15 mm.

In some optional aspects, the base pad 20 can be configured to compressby less than 20%, 15%, 10%, or 5% of the thickness 22 when subjected toa pressure of 2 lbf/in².

In some aspects, the floor panel 12 can comprise polymer. For example,in some aspects, the floor panel 12 can comprise polyvinylchloride. Inexemplary aspects, the floor panel 12 can comprise vinyl tile. Infurther aspects, the floor panel 12 can comprise wood. In yet furtheraspects, the floor panel 12 can comprise cementitious panel subfloor. Inyet further aspects, the floor panel 12 can comprise a gypsum subfloor.In further aspects, the floor panel 12 can comprise self-levelingflooring material (e.g., a gypsum-type or other cementitious floortopping with tile or other flooring material thereon). In some aspectsthe floor panel 12 can be flexible and/or resilient. In some aspects,the floor panel 12 can include, but is not limited to, laminate,engineered, luxury vinyl tile (LVT), luxury vinyl plank (LVP), and/orsolid wood hard surface products.

In some aspects, the floor panel 12 can have a thickness from about 1 mmto about 15 mm. For example the floor panel 12 can have a thickness fromabout 2 mm to about 10 mm, or from about 2 mm to about 8 mm, or fromabout 2 mm to about 6 mm, or from about 3 mm to about 5 mm, for exampleabout 4 mm.

In various optional aspects, the floor panel 12 can have a width fromabout 4 inches to about 24 inches. For example, in some aspects, thefloor panel 12 can have a width from about 5 inches to about 10 inches.In various optional aspects, the floor panel 12 can have a length fromabout 24 inches to about 72 inches. In exemplary aspects, the floorpanel can have a width from about 5 inches to about 10 inches and alength from about 24 inches to about 72 inches. The floor panel 12 canhave a rectangular shape. The floor panel 12 can have a square shape.

Although generally described herein as a floor panel, in variousaspects, embodiments disclosed herein in accordance with the floor panel12 can be a decorative hard surface element that serves as floor, wall,or ceiling coverings. In various aspects, the floor panel 12 and thebase pad 20 can cooperate to form a decorative unit.

In exemplary aspects, the base pad 20 can comprise a nonwoven material.The nonwoven material can comprise as sheet or web structure bondedtogether by entangling fiber or filaments (and by perforating films)mechanically, thermally or chemically. For example, the nonwovenmaterial can comprise needlebond or spun bond material. In some aspects,the nonwoven material can comprise polyethylene, polypropylene,polyester, nylon, polystyrene, polylactic acid, or a combinationthereof. In some aspects, the nonwoven material can comprise, or consistof, or consist essentially of recycled polymer (post-industrial,post-consumer, etc.). In other aspects, the nonwoven material cancomprise virgin polymer.

In further aspects, the base pad 20 can comprise a woven material. Wovenmaterials have the appearance of two-sets of parallel threads interlacedat generally right angles to each other in the plane of the material.“Warp” yarns lie along the length of the material and “weft” yarns liein the transverse direction, i.e. extending along the width of thematerial. The type of fibers used to produce a woven textile can bemonofilament, multifilament, a combination of each type, or slit filmyarns. In some aspects, the woven material can be tape-spun, wherein theterm “tape-spun” yarn refers to yarn having a slit film yarn in the warpdirection and spun (relatively short staple length) yarn in the weftdirection. In some aspects, the woven material can be tape-tape, wherein“tape-tape” yarn refers to yarn having a slit film yarn both in the warpand the weft directions.

In exemplary aspects, the base pad 20 does not have any filler dispersedtherethrough. Accordingly, in some aspects, the base pad 20 can comprisea material that defines open space (e.g., air pockets) therein that arenot filled with filler. This can contrast to, for example, a materialdefining pockets and a filler dispersed through the material and atleast partially fills the pockets and can diminish acoustic performancequalities of the base pad. In various optional aspects, the base pad 20can comprise, consist of, or consist essentially of, nonwoven materialand air dispersed therethrough.

In still further aspects, the base pad 20 can comprise a filler.Suitable fillers include, but are not limited to, coal fly ash, calciumcarbonate, iron oxide, barium sulfate, silica, carbon black, graphite,talc, titanium dioxide, or any other filler known in the art. The fillercan impact the reduce the size or number of air pockets within the basepad 20. Still further, the filler can control the consistency of thebase pad and can reduce cost.

In exemplary aspects, the base pad 20 can comprise a plurality of fibers(e.g., nonwoven material), wherein at least a portion of the fibers canbe vertically oriented. Such fibers can help to decouple the floor panel12 from the surface below the base pad (e.g., subfloor) for improvedacoustic performance. For example, the vertically oriented fibers canresiliently space the floor panel 12 from the surface below the base pad20 so that impacts against the floor panel 12 are at least partlyattenuated, rather than transferring the impact directly to the surfacebelow.

In some optional aspects, the fibers of the entangled fiber structure ofthe base pad 20 can have a denier at or above 12. For example, in someaspects, the denier (per filament, or dpf) of the fibers of theentangled fiber structure of the base pad 20 can be about 15. In furtheroptional aspects, some or all of the fibers of the base pad 20 can havea denier below 12. In yet further aspects, the denier of the fibers canbe from about 4 to about 30, such as from about 6 to about 20, or fromabout 8 to about 15.

In some optional aspects in which the base pad 20 comprises nonwovenmaterial, the fibers of the nonwoven material can comprise a firstplurality of fibers having a first melting point and a second pluralityof fibers having a second melting point that is greater than the meltingpoint of the first plurality of fibers. For example, said first andsecond plurality of fibers can form a fiber batt (e.g., optionally, anonwoven fiber batt). The first and second plurality of fibers canoptionally be intermixed and entangled. The combination of fibers withdifferent melting points (e.g., normal melt and low melt polymers) canimprove the compressive strength of the base pad 20 under a floor panel12 while maintaining acoustic performance.

In some example embodiments, the base pad 20 can optionally comprise aspunbond material. The spunbond material can be produced by depositingextruded, spun filaments onto a collecting belt in a uniform, randommanner followed by bonding the fibers. For example, the extruded, spunfilaments can be deposited in a consistent weight but in a randomfashion. The extruded, spun filaments can be extruded onto a belt movingat a constant speed. The fibers are separated during the web layingprocess by air jets or electrostatic charges. The collecting surface isusually perforated to prevent the air stream from deflecting andcarrying the fibers in an uncontrolled manner. Bonding imparts strengthand integrity to the web by applying heated rolls or hot needles topartially melt the polymer and fuse the fibers together. Since molecularorientation increases the melting point, fibers that are not highlydrawn can be used as thermal binding fibers. In some aspects, thespunbond material can comprise mono-component filament, which can berelatively inexpensive as compared to bi-component filament. In otheraspects, the spunbond material can comprise a bi-component filament of asheath-core type. In some aspects, the polymeric core component can havea higher melting point than the polymeric sheath component. In someaspects, the polymeric core component can comprise polyester, aliphaticpolyamides, polyphenylene oxide and/or co-polymers or blends thereof. Inyet other aspects, the polyester can comprise polyethyleneterephthalate, polybutylene terephthalate, or polyparaphenyleneterephthalamide. In yet other aspects, the polymeric core comprisespolyethylene terephthalate. In further aspects, the sheath polymer cancomprise a polyamide, polyethylene, or polyester. In yet furtheraspects, the sheath polymer comprises nylon. In still further aspects,the base pad comprises a polyester as a core component and nylon as asheath component.

In some aspects in which the base pad comprises nonwoven material, thenonwoven material can comprise needlebond (e.g., structured needlebond).The needlebond can have barbed needles penetrated therethrough to form astabilized web structural integrity. The needlebond can optionally behighly textured and have a coarse denier.

Optionally, the base pad 20 can comprise a single layer. In furtheraspects and with further reference to FIG. 2 , the base pad 20 cancomprise a plurality of layers. For example, the base pad 20 cancomprise two layers, three layers, four layers, or more. In someaspects, the base pad 20 can comprise a first layer 30 and a secondlayer 32. The first layer 30 can be disposed between the second layer 32and the floor panel 12. In some aspects, the first layer 30 can bepositioned adjacent the second surface 17 of the floor panel 12.

Optionally, at least one layer of the plurality of layers of the basepad 20 can have a density that is different from another layer of theplurality of layers of the base pad 20. For example, the first layer 30of the base pad 20 can have a first density and the second layer 32 ofthe base pad 20 can have a second density that is less than the firstdensity. In this way, the first layer 30 can serve as a cap layer thatholds an adhesive 34 for coupling the base pad 20 to the floor panel 12.The relatively greater density of the first layer 30 can inhibitundesirable excess permeation of the adhesive 34 through the base pad20. In some aspects, the first density can be at least 10%, at least20%, at least 30%, at least 40%, at least 50%, at least 100% greaterthan the second density. In some examples, the first layer 30 of thebase pad 20 can have a lower density than the second layer 32.

In some optional aspects, the base pad 20 can comprise at least onelayer comprising nonwoven material and at least one layer comprisingwoven material. For example, the first layer 30 can be a woven materialand the second layer 32 can be a non-woven material. In some aspects,the first layer 30 comprising woven material can be positioned facing tothe second surface 17 of the floor panel 12. In this way, the firstlayer 30 can serve as a cap layer that holds an adhesive 34 for couplingthe base pad 20 to the floor panel 12. For example, the first layercomprising a woven material can have smaller pores than a non-woven,thereby inhibiting penetration of adhesive. Still further, the firstlayer 30 comprising the woven material can enable adhesive to be easilyspread thereon. In this way, the adhesive can be applied more easily andin a controlled quantity, as compared to being spread on a non-wovenmaterial. Still further, the first layer 30 comprising woven materialcan inhibit penetration of the adhesive to the subfloor or to lowerlayer(s), second layer 32, that diminish the properties (e.g.,flexibility or resilience) of the lower layer(s). For example,penetration of the adhesive can fill air gaps in the non-woven material,thereby changing the compression characteristics of the non-wovenmaterial and diminishing the effectiveness of the non-woven material.Still further, the first layer 30 comprising woven material can providerigidity to the base pad. For example, the woven material can inhibitelongation in one or both of warp and weft directions. Said rigidity canbe advantageous during installation, particularly so for double-stickembodiments (described below). In further aspects, the first and secondlayers 30, 32 can both comprise nonwoven materials. In further aspects,the first and second layers 30, 32 can both comprise woven materials. Insome example embodiments, the first layer 30 can comprise a non-wovenmaterial and the second layer 32 can comprise a woven material.

In some aspects, the system 10 can be a double stick system. Forexample, a first adhesive can couple the base pad 20 to the subfloor,and a second adhesive can couple the base pad 20 to the flooring panel12. Optionally, the first adhesive can be nonpermanent, and the secondadhesive can be permanent. Exemplary adhesives can include SHAW 200resilient adhesive provided by Shaw Industries Group, Inc. of Dalton,Ga.

Optionally, adjacent layers can be coupled together via adhesive. Infurther aspects, adjacent layers can be coupled together via fiberentanglement. For example, in some aspects, the first and second layers30, 32 can be integrally formed as a composite to form base pad 20. Forexample, the composite material can comprise a woven material as thefirst layer 30 and a nonwoven layer as the second material 32. Inexemplary aspects, the first and second layers 30, 32 can be provided asa fiber lock weave or “FLW.” FLW is a (fabric) material that includesfibers needle punched into it. The adhesive 34 can be disposed betweenthe woven material and the floor panel 12. The woven material canadvantageously distribute the load of the floor panel 12 to the nonwovenmaterial. The woven material can further provide different mechanisms toachieve sufficient dimensional stability. Woven material can comprisewarp and weft threads or yarns that provide greater strength in a planardirection as compared to non-woven material. Strength of the wovenmaterial can be determined by yarn type, yarn count, fiber density,stiffness, fiber type, weave density, etc.

The first layer 30 of the base pad 20 can have a first side 40 thatfaces and opposes the floor panel 12 and an opposed second side 42.Optionally, the first side 40 can have a surface profile that isdifferent from the surface profile of the second side 42. For example,the surface profile of the second side 42 can comprise a plurality offibers (e.g., optionally, stray ends of fibers) that provide a shallowdecreasing fiber density (in terms of change in fiber density per changein thickness) in a direction away from the second side 42 and toward thefirst side 40, whereas the first 40 side has a surface profile thatdefines a more sharply decreasing fiber density in a direction away fromthe first side. In this way, the second side 42 can be fuzzier than thefirst side 40. It is contemplated that the fuzzier second side 42 canpreferably face away from the floor panel 12 so that the first side 40can receive adhesive without permitting undesired amount of adhesivepermeation. In exemplary aspects, the first layer 30 can comprise dilournonwoven material. In these aspects, optionally, the first layer 30 canbe the only layer of the base pad 20. In further aspects, the base pad20 can comprise two or more layers, with the first layer 30 adjacent tothe floor panel 12.

Referring to FIG. 3 , in some aspects, a barrier 50 (e.g., a film layer)can be disposed between the base pad 20 and the floor panel 12. Thebarrier 50 can optionally be liquid-impermeable. In this way, a levelingmaterial 52 can be positioned on the barrier 50. A tile or othersurfacing material 54 can be positioned on top of the leveling material52 (opposite the barrier 50). Optionally, the barrier 50 can bebreathable (e.g., a semipermeable fluid barrier). Optionally, the basepad 20 can be treated for water repellency. In these aspects, the basepad 20 can optionally receive leveling material 52 applied directlythereon. Optionally, the barrier can be coupled to the base pad 20. Infurther aspects, the barrier 50 can be a separate component that isplaced onto the base pad 20 prior to application of the levelingmaterial 52.

As described herein, the term “semipermeable” refers to materials thatdo not allow certain substances to permeate but do allow certain otherspecified materials to pass through it. For example, and withoutlimitation, a semipermeable fluid barrier can be permeable to gases andimpermeable to liquids, or vice versa. As described herein, the term“impermeable” refers to materials that do not allow the disclosedsubstances to pass through it. For example, and without limitation, afluid impermeable material can be impermeable to both liquids and gases.Liquid permeable can be impermeable to liquid but can optionally bepermeable to gasses.

In some aspects, the barrier 50 can comprise a polymer film. In theseaspects, the polymer film can comprise a thermoplastic material. In yetother aspects, the polymer film is a thermoplastic film. In otheraspects, the polymer film comprises polymers and copolymers ofpolyethylene, polypropylene, polyurethane, polyester, polyvinylchloride,nylon and polyethylene vinyl acetate. In yet other aspects, the polymerfilm comprises polyethylene, polypropylene, polyurethane, polyester, orpolyvinylchloride, or a combination thereof. In a yet further aspect,the polymer film is polyethylene. In yet further aspects, the polymerfilm is a combination of polyethylene and polyester.

In certain aspects, the polymer film is an extruded film. In yet otheraspects, the polymer film is a blown film. In a yet further aspect, thepolymer film is a cast film. In a still further aspect, the polymer filmis an engineered film. The term “engineered film” as used herein refersto a polymer film comprising same or different polymers and copolymers,wherein the film is formed by various techniques to ensure desirableproperties. In some aspects, the engineered film is a reinforced film.In some aspects, and without limitation, the engineered reinforced filmcan comprise a plurality of layers of the same or different polymer orcopolymer. In other aspects, the engineered film can comprise layers ofpolyethylene film sandwiched with a layer of polyester. In yet furtheraspects, the engineered film can comprise layers of polyethylene andpolypropylene, or layers of polyethylene and chemically resistantethylene vinyl alcohol (EVOH) copolymer. In certain aspects, theengineered film used in the current disclosure can be purchased fromRaven Industries.

In still further aspects, the polymer film is a composite filmcomprising polyethylene and polypropylene. In yet other aspects, thepolymer film can comprise a polypropylene core. In yet other aspects,the polymer composite film can comprise at least two layers. In otheraspects, the polymer composite film can comprise at least three layers.It is understood that each layer of the polymer composite film can besame or different and can comprise any of the polymers listed above. Insome aspects, the composite film comprises at least three layers, andwherein each outer layer of the composite film comprises polyethylene.

In some aspects, the polymer film disclosed herein is a fluid barrier.In yet other aspects, the polymer film is fluid impermeable. In yetother aspects, the polymer film is semipermeable material. In certainaspects, the polymer film is semipermeable to gases. In some aspects,the polymer film is semipermeable to all atmospheric gases. In exemplaryaspects and without limitation, the polymer film is semipermeable tooxygen, hydrogen, carbon dioxide, carbon oxide, nitrogen, and the like.In yet other aspects, the polymer film is impermeable to gases. Incertain aspects, the polymer film is impermeable, for example, andwithout limitations, to volatile organic compounds (VOCs), methane,carbon dioxide, carbon oxide, radon, gasoline, benzene and the like. Inyet further aspects, the polymer film is impermeable to the vapors.

In certain aspect, the polymer film is impermeable to fluids. In oneaspect, the polymer film is impermeable to aqueous fluids. In anotheraspect, the polymer film is impermeable to non-aqueous fluids. In afurther aspect, the non-aqueous fluid is an organic fluid. In furtherexemplary aspects, the polymer film is impermeable to water, carbonateand non-carbonate beverages, juices, milk, wine, or any other alcoholsubstances, human or pet bodily fluids, food fluids, food processingfluids, rain, or snow.

As disclosed herein, in some aspects, the polymer film can have athickness of less than about 6 mils. In other aspects, the polymer filmcan have a thickness of exemplary values of about 5.5 mils, about 5mils, about 4.5 mils, about 4 mils, about 3.5 mils, about 3 mils, about2.5 mils, about 2 mils, about 1.5 mils, about 1 mil, and about 0.5 mils.In other aspects, the polymer film can have a thickness in any rangederived from any two of the above stated values. For example, andwithout limitation the polymer film can have thickness from about 1 milto about 5.5 mils, or from about 2 mils to about 4 mils, or from about 1mil to about 3.5 mils.

In other aspects, the polymer film can have a thickness greater than 6mils, although increasing thickness can correspond to increasing cost.For example, in some aspects, the polymer film can have a thickness ofgreater than about 10 mils. In other aspects, the polymer film can havea thickness of exemplary values of about 10 mils, about 15 mils, about20 mils, about 25 mils, about 30 mils, about 35 mils, about 40 mils,about 45 mils, about 50 mils, about 55 mil, about 60 mils, about 65mils, about 70 mils, about 75 mils, about 80 mils, about 85 mils, about90 mils, and about 100 mils. In other aspects, the polymer film can havea thickness in any range derived from any two of the above statedvalues. For example, and without limitation the polymer film can havethickness from about 10 mils to about 40 mils, or from about 30 mils toabout 50 mils, or from about 30 mil to about 80 mils.

In some aspects, the polymer film is continuous. In other aspects, thepolymer film is substantially free of perforations or pinholes. In yetother aspects, the polymer film is continuous and substantially free ofperforations.

In some aspects, the base pad 20 can have a density from about 4.5lb/ft³ to about 30 lb/ft³, from about 6 lb/ft³ to about 20 lb/ft³, orfrom about 8 lb/ft³ to about 12 lb/ft³ (e.g., about 9 lb/ft³). Inexemplary aspects, the base pad 20 can comprise a nonwoven material,wherein the nonwoven material has a density from about 4.5 lb/ft³ toabout 30 lb/ft³, from about 6 lb/ft³ to about 20 lb/ft³, or from about 8lb/ft³ to about 12 lb/ft³ (e.g., about 9 lb/ft³). Such high densitiescan be advantageous for providing sufficient support to prevent fatiguefractures of the floor panel 12.

In some optional aspects, the base pad 20 can compress by 25% whensubject to a pressure from 2.1 lbf/in² to about 10 lbf/in². In someoptional aspects, the base pad 20 can compress by less than 20%, 15%,10%, or 5% when subject to a pressure of 2 lbf/in². In further aspects,the base pad 20 can comprise a nonwoven material, wherein the nonwovenmaterial is compressible by 25% when subject to a pressure from 2.1lbf/in² to about 10 lbf/in², such as a pressure of 3 lbf/in², 4 lbf/in²,5 lbf/in², 6 lbf/in², 7 lbf/in², 8 lbf/in² 9 lbf/in², or 10 lbf/in². Infurther aspects, said nonwoven material can compress by less than 20%,15%, 10%, or 5% when subject to a pressure of 2 lbf/in².

Hard surface flooring (hereinafter, also “hard flooring”) isincreasingly replacing carpet in buildings such as condominiums,apartments, and offices. Unlike carpet, hard flooring promotesundesirable sound (particularly, that which is transmitted to thedownstairs floor below) when subject to impact such as walking, petmovement, furniture placement, etc. Accordingly, as carpet is replacedwith hard flooring, activities consistent with normal use such aswalking, moving chairs, and accidentally dropping items that wouldgenerate little to no appreciable noise on carpeted surfaces now conductsignificant noise from the hard flooring, through the ceiling of thedownstairs floor below.

Many building codes mandate particular acoustical performancerequirements for impact sound. Further, beyond code minimums, peoplegenerally prefer maximal acoustic performance to isolate sound generatedby upstairs neighbors, and residents often prefer or demand performancebeyond code minimums.

An underlayment, whether integral to or installed beneath a hardflooring product, can be used to reduce the noise impacts from one spaceto another and to increase sound absorption within a space. Thefundamental design challenges of a resilient matting that is integral toor in addition to a finish floor is a balance between the acousticalperformance and the structural integrity of the system. The system musthave the ability to withstand the loading of objects, be comfortable towalk on, etc., but must also be effective at reducing the sound fromimpacts in the floor ceiling assembly. Further, the system needs to beas low in profile (i.e. height) as possible, since traditional floorinstallations are subject to real world conditions like door opening andclosing, transitions between different finish materials, etc.Traditionally, this has limited the acoustical performance of thematerials within a particular level of design.

There are several acoustical ratings that are used to measure andevaluate impact noise (higher ratings correspond to better soundinsulation). Impact Insulation Class or IIC is the traditional rating;most building codes require a minimum rating of IIC 50 for separatingfloor-ceiling assemblies in multifamily residential properties.High-frequency Impact Insulation Class or HIIC is a new acousticalrating that measures impact noise in the high-frequency range (400-3150Hz), which is the frequency range that describes the isolation providedby flooring and resilient matting products. Noise in the high-frequencyrange can be generated by walking in high heeled shoes, sounds from ametal, such as the use of a metal hammer, pets walking with toenailscontacting the floor, such as a dog walking on the floor, and itemsdropped on the floor.

An HIIC rating of 63 or better is a high level of acoustical performanceand generally considered a preferred level of HIIC. For hard surfaceflooring with any of the existing resilient matting products on themarket, it is not generally possible to achieve HIIC ratings of 63 wheninstalled on a 6 inch concrete slab structural system without a dropceiling.

In some aspects, the system 10 can be configured to achieve aHigh-frequency Impact Insulation Class (HIIC) rating of at least 63, atleast 65, at least 66, at least 67, or at least 68 from a lab test on a6″ concrete floor with no (drop) ceiling. In some aspects, the system 10can be configured to achieve an Impact Insulation Class (IIC) rating ofat least 56, at least 58, at least 59, at least 60, or at least 61 froma lab test on a 6″ concrete floor with no (drop) ceiling. As can beunderstood by those skilled in the art, the above HIIC and IIC ratingscan be well above commercially available acoustic underlayments, andparticularly so for underlayments that are affordable to a typicalresidential consumer.

Disclosed is a method that can comprise installing the system 10 asdisclosed herein. In various aspects, the system 10 can be installed ona subfloor surface 110. The subfloor surface 110 can comprise, forexample, concrete, wood (e.g., plywood), or any other suitable subfloormaterial. Referring to FIG. 5 , optionally, the base pad 20 can first beplaced on the subfloor surface, and the floor panel 12 can subsequentlybe placed thereon. In some aspects, an adhesive can be deposited on thesubfloor surface 110 or on the bottom surface of the base pad 20 priorto placing the base pad on the subfloor surface. In some examples,adhesive can be applied to only a portion of the base pad 20. Forexample, adhesive can be applied along or near perimeter of the base pad20. In other aspects, the base pad 20 is not adhered to the subfloor andcan instead be floating. In these aspects, an adhesive can optionally bedeposited on the base pad 20 prior to placing the floor panel 12thereon. In these aspects, an adhesive can optionally be deposited onthe floor panel 12 prior to placing it on the base pad 20. In exemplaryaspects, in embodiments in which the base pad 20 comprises a first layer30 comprising a woven material layer and a second layer 32 comprising anonwoven material layer, the base pad 20 can be oriented with the secondlayer facing the subfloor surface 110. In further aspects, and withreference to FIG. 6 , the base pad 20 and floor panel 12 can be providedas a decorative unit 100 (FIG. 4 ) with the base pad coupled to thefloor panel 12, and said unit 100 can be placed on the subfloor surface110. In such aspects, the base pad 20 can have the same or substantiallythe same perimeter as that of the floor panel 12. For example, the basepad 20 and the floor panel 12 can have the same rectangular perimeter.In exemplary aspects, a pre-cut base pad 20 can be coupled to (e.g.,adhered to) the floor panel 12. Optionally, the base pad 20 of thedecorative unit 100 can comprise a first layer 30 and a second layer 32,wherein the first layer faces the floor panel 12, and said first layercan comprising nonwoven material, with the second layer 32 comprisingwoven material. It is contemplated that such an embodiment can beadvantageous for double-stick applications so that the woven materialengages the adhesive between the subfloor and the base pad. In stillfurther aspects, the base pad 20 can comprise two woven materials with anon-woven material therebetween. For example, woven material can definetop and bottom surfaces of the base pad 20 with a non-woven materialtherebetween. In this way, woven material can advantageously contactadhesive between both the base pad 20 and the floor panel 12 as well asbetween the base pad and the subfloor.

Referring to FIG. 7 , in further exemplary aspects, the base pad 20 canbe placed on the subfloor surface 110. The barrier 50 can be coupled tothe base pad 20 prior to placement of the base pad on the subfloor, orthe barrier can subsequently be placed on the base pad 20. Theself-leveling material 52 can be deposited on the barrier 50. The tileor other surfacing material 54 (shown in FIG. 3 ) can be positioned ontop of the leveling material 52 (opposite the barrier 50). In otheraspects, the barrier 50 can be coupled to the floor panel 12 prior toplacing the flooring panel on the base pad 20. The self-levelingmaterial 52 and tile or other surfacing material 54 can cooperate toform the floor panel 12.

In exemplary, optional aspects in which the base pad 20 comprisesnonwoven material, the nonwoven material can comprise fibers havingrespective lengths from about 1 inch to 5 inches. The nonwoven materialof the base pad 20 can optionally comprise low melt fibers or otherbinders. The nonwoven material of the base pad 20 can optionallycomprise woven materials comprising polypropylene (PP), polyethyleneterephthalate (PET) and/or other polymer. The base pad 20 can optionallycomprise a spunbond material with fibers needled into the material. Thebase pad 20 can optionally comprise melt blown, wet laid, or spun laidfibers. The nonwoven fibers can comprise one or more materials,including, for example, PP, PET, polylactic acid (PLA), nylon 6, nylon6-6, acrylics, cellulose or a combination thereof. Some or all of thefibers can be from post-industrial or post-consumer sources. Optionally,the fibers of the base pad 20 can be formed into nonwoven materials viacarding and cross lapping, airlay, or Vlap technologies. The nonwovenformed by these processes can be needled, cured in via heat, sprayedwith emulsion binders, powdered low melts, and adhesives to hold a shapeor thickness. In some aspects, the density of the base pad 20 canoptionally be from 6.25 lb/ft³ (100 kg/m³) to 37 lb/ft³ (600 kg/m³). Insome aspects, the density of the base pad 20 can be from about 4.5lb/ft³ to about 30 lb/ft³. The base pad can be provided under floorpanel (e.g., hard surface flooring materials comprisingpolyvinylchloride (PVC), PET, polyethylene (PE), MgO and with thicknessfrom about 2 mm to about 10 mm). In another aspect, the nonwovenmaterial can be needled in a manner in which to form a fabric with ahigh percentage of the base material having fibers protruding from theneedled surface (e.g., forming a fuzzy surface, or a velour diloureffect). In further aspects, the base pad 20 can comprise multiplelayers having different fuzziness. For example, the second layer 32 canbe fuzzier than the first layer 30. In further aspects, the second side26 of the base pad 20 can be fuzzier than the first side 24.

In exemplary aspects, the base pad 20 can comprise non-woven or wet-laidfiberglass material (e.g., non-woven or wet-laid fiberglass scrims), aswell as woven and non-woven thermoplastic materials (e.g. polypropylene,nylon and polyester). Optionally, in one exemplary aspect, the base pad20 can comprise a fiberglass mat with an acrylic binder in a weightrange from 0.7 to 2.5 ounces per square yard. In another optionalaspect, it is contemplated that the base pad 20 can comprise a wet-laidfiberglass scrim with a SBR latex, PVOH, PVC latex, or PVC plastisolbinder in a weight range of 0.4 to 2.5 ounces per square yard.

In exemplary aspects, the base pad 20 can comprise a non-woven material.Optionally, the base pad 20 can comprise a foam. The foam has airpockets, such as closed air pockets. The size and distribution of theair pockets can be controlled during manufacturing. For example, thesize and distribution of the air pockets can be controlled by adding oneor more fillers during the foaming process. Suitable fillers include,but are not limited to, coal fly ash, calcium carbonate, iron oxide,barium sulfate, silica, carbon black, graphite, talc, titanium dioxide,or any other filler known in the art.

Optionally, the base pad 20 can comprise a fleece material, such as forexample and without limitation, a fleeced nonwoven material, whereby apolymeric non-woven textile is needle-punched with staple fibers toprovide a fleeced polymeric non-woven material.

Optionally, the base pad 20 can comprise polypropylene, polyethyleneterephthalate (PET), polyethylene, or combinations thereof. For example,when a polypropylene fleece is used as a base pad 20, it is contemplatedthat the base pad 20, or the non-woven material of the base pad, can beprovided in an amount from 3 ounces/sq. yard to about 5 ounces/sq. yardor, in an amount of about 4 ounces/sq. yard. As another example, thebase pad can comprise a PET or polypropylene needlebond pad, orcombinations thereof, which can comprise virgin material, post-consumermaterial, post-industrial material, or combinations thereof, and whichcan optionally be provided in an amount ranging from about 4 ounces/sq.yard to about 30 ounces/sq. yard, or from about 12 ounces/sq. yard toabout 20 ounces/sq. yard, or from about 14 ounces/sq. yard to about 18ounces/sq. yard, or from about 12 ounces/sq. yard to about 15 ounces/sq.yard.

Optionally, in some aspects, the base pad 20 can be needle-punched. Inthese aspects, the base pad 20 can be heat-stabilized. Optionally, thebase pad 20 can comprise a pointbond material.

In some aspects, the base pad 20 can comprise a woven needle punchedpolypropylene material such as SoftBac® manufactured by Shaw Industries,Inc. In this exemplary aspect, this material has been enhanced by havingabout 1.5 ounce/sq. yard of polypropylene fibers or polyethyleneterephthalate fibers needle punched onto one side of it and has a totalbasis weight of about 3.5 ounce/sq. yard. This needle punched materialcan be laminated so as to have the polypropylene fibers embedded withinan adhesive layer.

In some exemplary embodiments, disclosed herein is a system 10comprising a base pad 20 having a thickness 22 from about 2 mm to about4 mm, for example about 3 mm) and a floor panel 12 having a thickness ofabout 3 mm to about 5 mm, for example about 4 mm. The system 10 cancomprise polyolefin. For example, the system 10 can comprise 100%polyolefin. In some aspects, the floor panel 12 can comprisepolyvinylchloride. In some aspects, the base pad 20 can comprise PET. Inexemplary aspects, the system 10 can comprise at least 70% recycledpolymer, such as 80% of recycled polymer. The base pad 20 can optionallyhave a weight from about from about 14 ounces/sq. yard to about 18ounces/sq. yard, such as for example about 17 ounces/sq. The system 10can have an IIC rating of at least 57, such as an IIC rating of 59according to ASTM E492-09/E989-06. The system 10 can have an HIIC ratingof at least 67, such as an HIIC rating of 69, according to ASTM E222 of69. The base pad 20 can be provided as a unit, provided in a roll,having an area of 1.82 meters by 18.29 meters, and be cut into suitablesized pieces depending on the size of the area to be installed. The basepad 20 can comprise a first layer 30 being a woven layer and a secondlayer 32 being a non-woven layer. The base pad 20 is placed on asubfloor such that the second layer 32 connects to the subfloor, and anadhesive layer is applied to the first layer 30 being the woven layer.The floor panel 12 is applied onto the adhesive and at least oneneighboring system 10 is connected via a tongue and groove connection.

As can be understood, conventionally, elevating hard surface flooringfrom a subfloor has been understood to be undesirable, as it results infloor unevenness and sagging. For example, a thick, soft padding canprovide significant sound attenuation, but can lead to sagging or unevenflooring. Thin, hard padding typically provides substantially littlesound attenuation. Advantageously, fiber (e.g., nonwoven) material withsufficiently high density as disclosed herein can achieve previouslyunattained sound insulating characteristics without the detriment ofuneven or sagging flooring. Further, embodiments disclosed herein can bemanufactured for a relatively low price as compared to otheracoustic-improving elements, and particularly so as compared to the mosteffective alternative acoustic-improving elements. For example, foamrubber and crumb rubber can be prohibitively expensive for mostcommercial and residential applications. Embodiments disclosed hereincan advantageously reduce acoustic transmission for lower frequenciessuch as those generated by dropped items, medium frequencies, such asthose generated by walking, and higher frequencies, such as those fromhigh heeled shoes and pet toenails. For example, referring to the tablein FIG. 8 , rows 8-14 illustrate acoustic properties of exemplarysystems 10 as disclosed herein with comparisons to related underlaymentsshown in rows 1-7. As can be seen, the system 10 can provide superioracoustic properties over conventional underlayments. FIG. 9 showsacoustic properties of an exemplary system 10 as disclosed herein withcomparisons to related underlayments and carpet. As can be seen, thedisclosed exemplary system 10 can provide similar acoustic properties tocarpet.

Referring to FIG. 10 , in some exemplary aspects, the floor panel 12 canbe a hard surface floor panel that comprises a substrate 70 and adecorative portion 60 (e.g., décor, wear and scratch layer, and/or anyappropriate intermediate layers) coupled to the substrate 70. Thedecorative portion can comprise one or more layers including, but notlimited to, an image layer, a wear layer, and/or a scratch layer. Insome example aspects, there may be an additional layer such as abalancing layer (e.g., melamine impregnated paper, etc.) attached to thebottom surface of the substrate 70. As described above and shown atleast in FIGS. 6 and 7 , the base pad 20 may be integrally attached tothe bottom surface of the floor panel 12, or the base pad 20 could besold separately and configured to be attached to the floor panel 12.

As described in detail herein, and with further reference to FIGS. 1 and6 , the decorative unit 100 can comprise a floor panel 12 and base pad20 coupled thereto. In some examples, the base pad 20 can be coupled tothe floor panel on the second side 16 of the floor panel. In additionalor alternative aspects, the decorative unit 100 can comprise a floorpanel 12 with the base pad 20 embedded therein between the first side 14and the opposing second side 16 of the floor panel 12. For example, insome aspects, the base pad 20 (e.g., comprising a nonwoven and,optionally, one or more woven layers) may be disposed between thedecorative portion 60 and the substrate 70, see FIG. 10 . For example,the base pad 20 may be disposed between the décor or image layer and thesubstrate 70. In some examples, the structure may be disposed in thesubstrate 70 as described below in greater detail. In still furtheraspects, the decorative unit 100 comprising a base pad 20 embeddedtherein (e.g., between the decorative portion 60 and substrate 70) canfurther comprise an additional base pad 20 below substrate 70.Optionally, the decorative unit 100 can comprise a first base padembedded therein and a second base pad coupled to the lower surface ofthe substrate 70. In other aspects, the decorative unit 100 can comprisea first base pad embedded therein, and a second base pad can bepositioned below, but not coupled to the substrate 70. In still otheraspects, the decorative unit 100 can comprise a first base pad embeddedtherein, and a separate underlayment (e.g., a cork underlayment) can bepositioned below the decorative unit.

The decorative portion 60 may also be interchangeably referred to as thetop layer since said layer 60 may serve a decorative function as well asadditional functions/purposes like providing scratch-resistance,moisture resistance, etc. The decorative portion 60 can serve to definethe aesthetic look of the floor panel 12. In various aspects, thedecorative portion can comprise a single layer or a plurality of layers.For example, the decorative portion 60 can comprise a decorative surfacelayer that defines at least one aesthetic characteristic (e.g., color,pattern, texture, glossiness, etc.), in addition to or instead ofserving a structural, acoustic, etc., or other purpose. Optionally, thedecorative portion 60 can comprise an image layer (e.g., a printedlayer). In some examples, the décor layer may be printed directly on thesubstrate or on an ink receiving layer(s) disposed on the substrate 70.The decorative portion can further comprise one or more upper layers(e.g., a wear layer and/or a scratch layer) that may serve multiplepurposes (texture, scratch resistance, gloss, etc.). Thus, in someoptional aspects, each layer of the decorative portion 60 can impart atleast one aesthetic characteristic of the floor panel. In some exemplaryembodiments, the decorative portion 60 can be embodied in accordancewith the decorative portion of the layered composite article describedin U.S. Patent Application Publication No. 2018/0134016, published May17, 2018, the entirety of which is hereby incorporated by referenceherein.

The substrate 70 can include, but is not limited to, composite materialsuch as, but not limited to, wood polymer composite, a wood plasticcomposite, a stone plastic composite, etc. The substrate can alsoinclude a mineral substrate such as a magnesium oxide substrate that isformed by a mixture of magnesium oxide, magnesium salts, and additives(e.g., wood fibers).

In some aspects, the substrate 70 can have a plurality of layersarranged in a layered structure. The layers can have differentproperties. In exemplary aspects, the substrate can have an arrangementof layers provided in an ABA structure. The ‘A’ layers and the ‘B’layer(s) can impart different characteristics to the substrate. In someaspects, the ‘B’ layer(s) can include, but is not limited to, a foamedmaterial, a nonwoven material, etc. ‘A’ layers can include, but is notlimited to, composite materials, engineered hardwood materials, etc. Insome examples, ‘B’ layer(s) can comprise a breathable material. In otherexamples, ‘B’ layer(s) can be both breathable and dimensionally stable.It is noted that ‘B’ layer(s) can be structured as a pad that is rigidor flexible. Further, ‘B’ can be structured to fit as a layer in betweenthe ‘A’ layers. In some examples, additives such as fiberglass, fibers(wood or hemp fibers), etc., can add/provide dimensional stability tothe ‘A’ layer(s) or the ‘B’ layer(s). Composite materials that can beused in the ‘A’ layer(s) can include, but are not limited to, woodpolymer or wood plastic composite, stone polymer or stone plasticcomposite, mineral composite (magnesium oxide composite, etc.), LVT,LVP, etc. In one example, the foamed material can include an irradiatedcross-linked polyethylene (IXPE) pad. In one example, the nonwovenmaterial can include a pad made of fibers that are needled together ortwisted together (not extruded or foamed). The base pad 20 can bestructured as a panel, board, tile, etc., that is rigid anddimensionally stable. In one example, the nonwoven material can be anonwoven panel as described in any one of U.S. Patent ApplicationsPublication Nos. 2018/0134016, published May 17, 2018; 2021/0370654,published Dec. 2, 2021; or 2022/0161519, published May 26, 2022, each ofwhich is incorporated herein by reference in its respective entirety. Inanother example, ‘B’ layer(s) can be embodied as the base pad 20described herein. The ABA structure can be arranged such that thedensity of layer ‘B’ is lower than the density of the ‘A’ layers. Inother examples, the density of layer(s) ‘B’ can be higher than thedensity of the ‘A’ layers. In some examples, one layer A may bedifferent in construction, composition, density, and/or structure fromthe other layer A in the ABA structure.

In various exemplary embodiments, layer(s) ‘B’ can include a singlelayer or multiple layers. For example, layer ‘B’ can include layers B1,B2, etc. Each of the multiple layers (B1, B2, . . . etc.) can bebreathable layers. Each of the multiple layers (B1, B2, . . . etc.) canbe different from each other in construction, structure, and/orcomposition. The multiple layers (B1, B2, . . . etc.) can have the sameor differing densities. For example, layer B can have 3 sub layers B1-B3arranged such that B2 is sandwiched between B1 and B3 and layer B2 canhave a higher density than B1 and B3. In alternative aspects, B2 canhave a lower density than B1 and B3. Alternatively, the density of thesublayers can increase or decrease (e.g., changing gradually) from topto bottom (i.e., from B1 to B3). In one example, the multiple layers(B1, B2, . . . etc.) can be nonwovens. Alternatively, the multiplelayers can be a combination of woven and non-woven without departingfrom a broader scope of the present disclosure. For example, B1 may be awoven and B2 may be a non-woven as described above with respect to thebase pad 20.

In some other aspects, the substrate may have other structures and isnot limited to the ABA structure. For example, the substrate can beABABA structure. In these aspects, the B layers can be breathablematerial and can also be dimensionally stable. The thickness of thesubstrate can range from 2 mm to 12 mm (both end values included)without departing from a broader scope of the disclosure. Like layer‘B’, as described above, in some examples, layer A may can includemultiple other layers (sub layers, e.g., A1, A2, etc.) that may besimilar or different from each other in construction, structure, densityand/or composition. The substrate structures described above can furtherimprove in-room and below room acoustics of the floor panel 12 (i.e., inaddition to or in lieu of using the base pad 20 at the bottom of thefloor panel 12).

In still further aspects, an article can comprise a base pad 10 with animage layer printed thereon, or otherwise coupled to, the upper surfaceof the base pad. Said article can further comprise a wear layer and ascratch layer above the wear layer. Optionally, in these aspects, thesubstrate 70 can be omitted from the article.

In addition to improved acoustic properties, the disclosed systems,methods, and flooring elements can provide improved comfort, minimizedindentation and sagging, ease of installation, and various other factorsthat will be apparent to those skilled in the art.

System Having a Stiffening Structure Between Decorative Element andAcoustic Article

Referring to FIG. 11 , also disclosed herein is a system 10 comprising adecorative element 12 having a first side 14 and an opposing second side16. The decorative element 12 has a first surface 15 on the first side14 and a second surface 17 on the opposing second side 16. An acousticarticle 20 is disposed on the opposing second side 16 of the decorativeelement 12. The acoustic article 20 has a thickness 22 between a firstside 24 and an opposed second side 26. The acoustic article 20 comprisesa resiliently compressible material. The acoustic article 20 has athickness of at least 0.4 mm. The acoustic article 20 is compressible byless than 25% of the thickness when subjected to a pressure of 2lbf/in². A stiffening structure 80 is disposed between the decorativeelement 12 and the acoustic article 20.

Accordingly, in some aspects, the stiffening structure 80 can bepositioned between the decorative element (floor panel) and the acousticarticle (base pad). The stiffening structure 80 positioned between thedecorative element and the acoustic article can provide variousadvantages further disclosed herein.

The stiffening structure 80 can provide an increased stiffness to theacoustic article 20 in comparison to an acoustic article with thestiffening structure omitted. In some aspects, the stiffness of can becharacterized in accordance with ASTM D1388-18.

In some aspects, the stiffening structure 80 and the acoustic article 20can cooperate to provide a stiffness of at least 40,000microjoules/meter (in accordance with the testing procedure of ASTMD1388-18). That is, an assembly of the stiffening structure 80 coupledto the acoustic article 20, when tested in accordance with the testingprocedure of ASTM D1388-18, can provide a measurement of at least 40,000microjoules/meter. Even though the acoustic article 20 and thestiffening structure 80 may not necessarily be provided in isolation, itshould be understood that the material properties of the acousticarticle 20 and the stiffening structure 80 can be such that themeasurement would be achieved had the acoustic article 20 and thestiffening structure 80 been provided in isolation. It is contemplatedthat the measurement according to ASTM D1388-18 can vary based on theorientation of the material (e.g., with the stiffening structure aboveor below the acoustic article). In these aspects, the measurementaccording to ASTM D1388-18 can be the orientation of the material in ause condition. In some aspects, the stiffening structure 80 and theacoustic article 20 can cooperate to provide a stiffness of at least50,000 microjoules/meter. In some aspects, the stiffening structure 80and the acoustic article 20 can cooperate to provide a stiffness of atleast 60,000 microjoules/meter. In some aspects, the stiffeningstructure 80 and the acoustic article 20 can cooperate to provide astiffness of at least 70,000 microjoules/meter. In some aspects, thestiffening structure 80 and the acoustic article 20 can cooperate toprovide a stiffness of at least 80,000 microjoules/meter. In someaspects, the stiffening structure 80 and the acoustic article 20 cancooperate to provide a stiffness of at least 90,000 microjoules/meter.In some aspects, the stiffening structure 80 and the acoustic article 20can cooperate to provide a stiffness of at least 100,000microjoules/meter. In some aspects, the stiffening structure 80 and theacoustic article 20 can cooperate to provide a stiffness of at least110,000 microjoules/meter. In some aspects, the stiffening structure 80and the acoustic article 20 can cooperate to provide a stiffness of atleast 120,000 microjoules/meter. In some aspects, the stiffeningstructure 80 and the acoustic article 20 can cooperate to provide astiffness of at least 130,000 microjoules/meter. In some aspects, thestiffening structure 80 and the acoustic article 20 can cooperate toprovide a stiffness of at least 140,000 microjoules/meter. In someaspects, the stiffening structure 80 and the acoustic article 20 cancooperate to provide a stiffness of at least 150,000 microjoules/meter.In some aspects, the stiffening structure 80 and the acoustic article 20can cooperate to provide a stiffness of at least 160,000microjoules/meter. In some aspects, the stiffening structure 80 and theacoustic article 20 can cooperate to provide a stiffness of no more than500,000 microjoules/meter. In other aspects, the stiffening structure 80and the acoustic article 20 can cooperate to provide a stiffness thatexceeds 500,000 microjoules/meter. In some aspects, the stiffeningstructure 80 and the acoustic article 20 can cooperate to provide astiffness from about 40,000 microjoules/meter to about 500,000microjoules/meter. In some aspects, the stiffening structure 80 and theacoustic article 20 can cooperate to provide a stiffness from about50,000 microjoules/meter to about 200,000 microjoules/meter.

In some aspects, the stiffness of the acoustic article with stiffeningstructure can be greater than the stiffness of the acoustic articlewithout the stiffening structure. For example, the stiffness of theacoustic article with stiffening structure can be greater than or equalto 2 times the stiffness of the acoustic article without the stiffeningstructure. That is, an assembly of the stiffening structure 80 coupledto the acoustic article 20, when tested in accordance with the testingprocedure of ASTM D1388-18, can provide a measurement that is at least 2times the stiffness of the acoustic article without the stiffeningstructure when using the same testing procedure. Even though theacoustic article 20 and the stiffening structure 80 may not necessarilybe provided in isolation, it should be understood that the materialproperties of the acoustic article 20 and the stiffening structure 80can be such that these measurements, providing the 2:1 stiffness ratio,would be achieved had the acoustic article 20 and the stiffeningstructure 80 been provided in isolation. In some aspects, the stiffnessof the acoustic article with stiffening structure may be greater than orequal to 3 times the stiffness of the acoustic article without thestiffening structure. In some aspects, the stiffness of the acousticarticle with stiffening structure may be greater than or equal to 4times the stiffness of the acoustic article without the stiffeningstructure. In some aspects, the stiffness of the acoustic article withstiffening structure may be greater than or equal to 5 times thestiffness of the acoustic article without the stiffening structure. Insome aspects, the stiffness of the acoustic article with stiffeningstructure may be greater than or equal to 6 times the stiffness of theacoustic article without the stiffening structure. In some aspects, thestiffness of the acoustic article with stiffening structure may begreater than or equal to 7 times the stiffness of the acoustic articlewithout the stiffening structure. In some aspects, the stiffness of theacoustic article with stiffening structure may be greater than or equalto 8 times the stiffness of the acoustic article without the stiffeningstructure. In some aspects, the stiffness of the acoustic article withstiffening structure may be greater than or equal to 9 times thestiffness of the acoustic article without the stiffening structure. Insome aspects, the stiffness of the acoustic article with stiffeningstructure may be greater than or equal to 10 times the stiffness of theacoustic article without the stiffening structure. In some aspects, thestiffness of the acoustic article with stiffening structure may begreater than or equal to 11 times the stiffness of the acoustic articlewithout the stiffening structure. In some aspects, the stiffness of theacoustic article with stiffening structure may be greater than or equalto 12 times the stiffness of the acoustic article without the stiffeningstructure. In some aspects, the stiffness of the acoustic article withstiffening structure may be greater than or equal to 13 times thestiffness of the acoustic article without the stiffening structure.

In some aspects, the ratio of a density of stiffening structure to adensity of the acoustic article (D_stiffening_structuretop/D_acoustic_pad) can be greater than 1. In some examples, thestiffening structure_can be at least 1.1 times, at least 1.2 times, atleast 1.3, at least 1.5 times, at least 2 times, at least 3 times, atleast 5 times, at least 10 times, or at least 30 times that of thedensity of the acoustic article. In some examples, the density of thestiffening structure_can be the same as, or substantially the same as,the density of the acoustic article.

In some aspects, the stiffening layer can have a thickness of less than⅓ of a combined thickness of the stiffening layer and the acousticarticle. In some aspects, the stiffening layer can have a thickness ofless than ½ of the combined thickness of the stiffening layer and theacoustic article. In some aspects, the stiffening layer and the acousticarticle can have a combined thickness from about 0.4 to about 25 mm.

In some aspects, the acoustic article 20 can be the resilientlycompressible material. Thus, in some aspects, the resilientlycompressible material can have a thickness of at least 0.4 mm and cancompress by less than 25% of the thickness when subjected to a pressureof 2 lbf/in².

In some aspects, the stiffening structure 80 consists of a single layer.For example, in some aspects, the stiffening structure 80 can consist ofa single thermoplastic layer. In other aspects, and with furtherreference to FIG. 12 , the stiffening structure 80 can comprise aplurality of layers. For example, the plurality of layers can belaminated together. In some aspects, the plurality of layers cancomprise a layer of thermoplastic 82 and a structural stabilizer 84. Insome optional aspects, the plurality of layers can comprise twothermoplastic layers 82. For example, the plurality of layers cancomprise a structural stabilizer 84 laminated between the twothermoplastic layers 82. In exemplary aspects, the thermoplastic can bevinyl, rubber, polyolefin, polyester, or a combination thereof. In someaspects, the thermoplastic layer(s) can be provided as a polymer film.In various aspects, the structural stabilizer can comprise fiberglass,woven fabric, non-woven fabric, or a combination thereof. In someexample aspects, the stiffening structure 80 can vary from 100% fiber toa mix of fiber and rubber at any ratio.

In some aspects, the stiffening structure can comprise a rigid fabric.Such a rigid fabric can be, for example, a structured non-woven. Thestructured non-woven can comprise a highly singed low melt fiber.Optionally, the stiffening structure 20 can consist of a rigid fabric.

In some aspects, the stiffening structure 80 can comprise one or morepolymer films. Optionally, said polymer can be rubber. In some aspects,the stiffening structure 80 can comprise PET Hybrid (a composite articleas described in U.S. Pat. No. 11,603,611, issued Mar. 14, 2023, which isincorporated herein by reference). In some aspects, the stiffeningstructure 80 can comprise a nonwoven panel as described in any one ofU.S. Patent Applications Publication Nos. 2018/0134016, published May17, 2018; 2021/0370654, published Dec. 2, 2021; or 2022/0161519,published May 26, 2022, each of which is incorporated herein byreference in its respective entirety. In some aspects, the stiffeningstructure 80 can comprise vinyl.

In some aspects, the stiffening structure 80 can be coupled to theacoustic article 20. For example, in some optional aspects, thestiffening structure 80 can be adhesively coupled to the acousticarticle 20. In other aspects, the stiffening structure 80 can be bonded(e.g., thermally bonded) to the acoustic article 20.

In some aspects, the decorative element 12 can be coupled to thestiffening structure 80. For example, the decorative element 12 can beadhesively coupled to the stiffening structure 80. In other aspects, thedecorative element 12 is not coupled to the stiffening structure 80. Forexample, the decorative element 12 can be said to be “floating.”

In some aspects, the stiffening structure 80 comprises a first pluralityof fibers having a first melting point, and the acoustic article 20 cancomprise a second plurality of fibers having a second melting point thatis higher than the first melting point. At least a portion of the firstplurality of fibers can melted to form the stiffening structure. In someaspects, all, or substantially all of the first plurality of fibers canbe melted to form the stiffening structure. Accordingly, in someaspects, the stiffening structure 80 and the acoustic article 20 can beintegrally formed together. Optionally, the first and second pluralityof fibers can be entangled together prior to melting the at least aportion of the first plurality of fibers to form the stiffeningstructure. Accordingly, an intermediate structure can comprise aplurality of the acoustic article and a first plurality of fibers,wherein the first plurality of fibers are positioned against orentangled with the acoustic article. Upon melting a portion of or all ofthe first plurality of fibers, the melted fibers can form the stiffeningstructure that is coupled to the acoustic article 20 by integralformation. In some embodiments, in which the stiffening structure 80 isintegrally attached to the acoustic article 20, such a stiffeningstructure can be formed by placing the stiffening structure 80 on theacoustic article 20 and by melting a portion of or all of the firstplurality of fibers to adhere to the stiffening structure 80. In otheraspects, the stiffening structure 80 can be first formed separately fromthe acoustic article and then attached to the acoustic article 20. Forexample, first plurality of fibers can be melted to form the stiffeningstructure 80, and said stiffening structure can subsequently be coupledto the acoustic article 20.

In some aspects, the resiliently compressible material of the acousticarticle comprises an entangled fiber structure. For example, theentangled fiber structure can comprise, or can be, a needle bondedfabric. In other aspects, the entangled fiber structure can comprise, orcan be, any other entangled fiber structure disclosed herein. Forexample, the entangled fiber structure can comprise nonwoven material.The nonwoven material can comprise as sheet or web structure bondedtogether by entangling fiber or filaments (and by perforating films)mechanically, thermally or chemically. For example, the nonwovenmaterial can comprise needlebond or spun bond material. In some aspects,the nonwoven material can comprise polyethylene, polypropylene,polyester, nylon, polystyrene, polylactic acid, or a combinationthereof. In some aspects, the nonwoven material can comprise, or consistof, or consist essentially of recycled polymer (post-industrial,post-consumer, etc.). In other aspects, the nonwoven material cancomprise virgin polymer.

In some aspects, the acoustic article can have only one single layer.Referring also to FIG. 2 , in some aspects, the acoustic article 20 cancomprise a plurality of layers. For example, in some optional aspects,the acoustic article 20 can comprise at least one layer comprisingnonwoven material and at least one layer comprising woven material. Forexample, a first layer 30 can be a woven material and a second layer 32can be a non-woven material. In some aspects, the first layer 30comprising woven material can be positioned facing to the second surface17 of the floor panel 12. Still further, the first layer 30 comprisingwoven material can provide rigidity to the acoustic article. Forexample, the woven material can inhibit elongation in one or both ofwarp and weft directions. In further aspects, the first and secondlayers 30, 32 can both comprise nonwoven materials. In further aspects,the first and second layers 30, 32 can both comprise woven materials. Insome example embodiments, the first layer 30 can comprise a non-wovenmaterial and the second layer 32 can comprise a woven material.

More generally, the acoustic article can be embodied as described inother sections of this present disclosure.

In some aspects, the resiliently compressible material of the acousticarticle can comprise a non-woven material. In some aspects, theresiliently compressible material of the acoustic article can comprisefoam, rubber, or composite. In other aspects, the resilientlycompressible material of the acoustic article can comprise cork. Invarious aspects, the resiliently compressible material of the acousticarticle can be a sound-absorbing material. In these aspects, optionally,the sound-absorbing material can include, but not be limited to, foam,rubber, composite, non-woven fabric, or cork. The foam can be aclosed-cell foam or an open-cell foam. The foam can be a polymer basedfoam, such as a polyurethane foam, polyethylene-vinyl acetate foam,polyethylene foam, polypropylene foam, polystyrene foam, silicone foam,or polyvinyl chloride foam. Composites can include, but not be limitedto, a resilient polymer with a reinforcement material dispersedtherethrough. Such a reinforcement material can include, for example,fiberglass, carbon fiber, carbon nanotubes.

In some aspects, the acoustic article and the stiffening structure canbe coupled together and provided as a unitary component. The unitarycomponent can serve as a subsurface article over which a decorativeelement can be placed.

Disclosed herein, in one aspect, is a subsurface article 90 comprisingan acoustic article 20 comprising a resiliently compressible material.The acoustic article 20 has a thickness of at least 0.4 mm and iscompressible by less than 25% of the thickness when subjected to apressure of 2 lbf/in². The acoustic article 20 has a first side 21. Thesubsurface article 90 further comprises a stiffening structure 80positioned on the first side 21 of the acoustic article 20.

Disclosed herein is a method of installing the system onto a subfloorsurface. In some aspects, the method can comprise placing an assemblycomprising the decorative element coupled to the acoustic article, withthe stiffening structure disposed between the decorative element and theacoustic article, on the subfloor surface. That is, the decorativeelement, the stiffening structure, and the acoustic article can becoupled together and installed together. In some examples, the unitcomprising the decorative element, stiffening structure, and theacoustic article may be installed as a floating floor. In other aspects,the unit comprising the decorative element, stiffening structure, andthe acoustic article may be installed as a floating floor may beinstalled using glue down installation (e.g., glue disposed on subfloorand the unit comprising the decorative element, stiffening structure,and the acoustic article is glued down to the subfloor such that glue oradhesive is disposed between a surface of the acoustic article facingthe subfloor and the subfloor). In some examples, the bottom surface ofthe acoustic article (i.e., surface that will face the subfloor uponinstallation) can be made sticky (e.g., backed with an adhesive) and canbe provided with a release paper. The release paper may be removed, andthe acoustic article can be stuck to the subfloor.

In alternative aspects, the acoustic article and the stiffeningstructure can be installed on the subfloor surface, and the decorativeelement can then be placed or installed on the stiffening structureeither using a glue down installation or as a floating floorinstallation. In some example aspects, the acoustic article andstiffening structure may be designed for loose lay installation.

As described above, in some aspects, an adhesive can be depositedbetween the stiffening structure and the decorative element for a gluedown installation.

Referring to FIGS. 4 and 11 , it is further contemplated that thedecorative unit 100, as disclosed herein, can incorporate a stiffeningstructure 80 between the decorative element 12 and the acoustic article20. The decorative unit 100 can be installed to form a surface covering,such as a floor covering, or a wall or ceiling covering.

Accordingly, disclosed herein, in one aspect, is a decorative unit 100comprising a decorative element 12 having a first side 14 and anopposing second side 16, wherein the decorative element has a firstsurface 15 on the first side 14 and a second surface 17 on the opposingsecond side 16. An acoustic article 20 is coupled to the decorativeelement 12 on the opposing second side of the decorative element. Theacoustic article comprises a resiliently compressible material, has athickness of at least 0.4 mm, and is compressible by less than 25% ofthe thickness when subject to a pressure of 2 lbf/in². A stiffeningstructure 80 is disposed between the decorative element and the acousticarticle.

Including the stiffening structure 80 in the system 10 can providevarious advantages. As one advantage, the stiffening structure 80 candistribute load on the decorative element 12 across the acoustic article20 to prevent deflection of the decorative element 12 when load isapplied thereto. For example, luxury vinyl tile (LVT) is an example of aflexible resilient decorative element that can deflect when load isapplied thereto. In certain situations and configurations, absent astiffening structure underneath to support the LVT, the LVT can deflectto an extent that the deflection leads to uneven flooring, interferewith couplings of adjacent LVT, or otherwise cause damage to the LVT.Further, the resiliently compressible material of the acoustic articlecan permit airflow therethrough. For example, the resilientlycompressible material can comprise entangled fiber or open cell foamthat permits airflow therethrough. In some situations, moisturepermeability can be desirable. However, in other situations, moisturepermeability can be undesirable. If moisture is present below theacoustic article, the stiffening structure can provide an impermeablebarrier that prevents moisture from reaching the decorative element.Instead, the moisture can dissipate laterally. In this way, for example,condensate on concrete surfaces can be inhibited. Still further, thestiffening structure 80 can receive adhesive for coupling the decorativeelement thereto. Inclusion of the stiffening structure 80 can preventadhesive from penetrating the resiliently compressible material, whichcan inhibit its compressibility as well as air permeability.

In some aspects, the system 10 comprising the stiffening structure 80can be configured to achieve a High-frequency Impact Insulation Class(HIIC) rating of at least 63, from a lab test on a 6″ concrete floorwith no (drop) ceiling when tested with a 2 mm Luxury Vinyl Tile orPlank installed above the system 10 with the stiffening structure 80. Infurther aspects, the system 10 comprising the stiffening structure 80can be configured to achieve a High-frequency Impact Insulation Class(HIIC) rating at least 64, from a lab test on a 6″ concrete floor withno (drop) ceiling when tested with a 2 mm Luxury Vinyl Tile or Plankinstalled above the system 10 with the stiffening structure 80. In someaspects, the system 10 with the stiffening structure 80 can beconfigured to achieve an Impact Insulation Class (IIC) rating of atleast 57 from a lab test on a 6″ concrete floor with no (drop) ceilingwhen tested with a 2 mm Luxury Vinyl Tile or Plank installed above thesystem 10 with the stiffening structure 80. In further aspects, thesystem 10 with the stiffening structure 80 can be configured to achievean Impact Insulation Class (IIC) rating of at least 58 from a lab teston a 6″ concrete floor with no (drop) ceiling when tested with a 2 mmLuxury Vinyl Tile or Plank installed above the system 10 with thestiffening structure 80. As can be understood by those skilled in theart, the above HIIC and IIC ratings can be well above commerciallyavailable acoustic underlayments, and particularly so for underlaymentsthat are affordable to a typical residential consumer. In some aspects,the system 10 with the stiffening structure 80 can be configured toachieve an Impact Insulation Class (IIC) rating of at least 56 from alab test on a 6″ concrete floor with no (drop) ceiling when tested witha 2 mm Luxury Vinyl Tile or Plank installed above the system 10 with thestiffening structure 80. As can be understood by those skilled in theart, the above HIIC and IIC ratings can be well above commerciallyavailable acoustic underlayments, and particularly so for underlaymentsthat are affordable to a typical residential consumer.

ASTM D1388-18 Simplified Description

Referring to FIGS. 13-14 , the material (e.g., acoustic article) orassembly (e.g., acoustic article and stiffening structure 80 attachedthereto) is pushed over the edge of a table. The measurement correspondsto the distance that the material or assembly extends from the edge atwhich point the end falls to a specified angle (41.5 degrees). Thestiffer the material/assembly, the longer the distance.

Exemplary Aspects

In view of the described products, systems, and methods and variationsthereof, herein below are described certain more particularly describedaspects of the invention. These particularly recited aspects should nothowever be interpreted to have any limiting effect on any differentclaims containing different or more general teachings described herein,or that the “particular” aspects are somehow limited in some way otherthan the inherent meanings of the language literally used therein.

Aspects labeled “A,” “B,” and “C” are provided as disclosure usingalternative terminology and do not indicate differentiated scope basedon the different terminology.

Aspect 1A: A system comprising:

-   -   a decorative element having a first side and an opposing second        side; and    -   an acoustic article configured to be disposed on the opposing        second side of the decorative element, wherein the acoustic        article:        -   comprises an entangled fiber structure;        -   has a thickness of at least 0.4 mm; and        -   is compressible by less than 25% of the thickness when            subjected to a pressure of 2 lbf/in².

Aspect 2A: The system of aspect 1A, wherein the decorative elementcomprises polymer.

Aspect 3A: The system of aspect 1A, wherein the decorative elementcomprises wood.

Aspect 4A: The system of aspect 1A, wherein the decorative elementcomprises cementitious panel subfloor.

Aspect 5A: The system of any one of aspects 2A-4A, wherein thedecorative element is flexible and resilient.

Aspect 6A: The system of any one of the preceding aspects, wherein theacoustic article has no filler dispersed therethrough.

Aspect 7A: The system of aspect 6A, wherein the acoustic articleconsists essentially of nonwoven material and air dispersedtherethrough.

Aspect 8A: The system of any one of the preceding aspects, wherein theacoustic article comprises a plurality of fibers having a denier above12.

Aspect 9A: The system of aspect 8A, wherein the denier is about 15.

Aspect 10A: The system of any one of the preceding aspects, wherein theacoustic article has a thickness from 0.4 mm to 25 mm.

Aspect 11A: The system of any one of the preceding aspects, wherein theacoustic article comprises a first plurality of fibers having a firstmelting point and a second plurality of fibers having a second meltingpoint that is greater than the melting point of the first plurality offibers.

Aspect 12A: The system of any one of the preceding aspects, wherein theacoustic article comprises a plurality of layers.

Aspect 13A: The system of aspect 12A, wherein the plurality of layershave different respective densities.

Aspect 14A: The system of any one of the preceding aspects, wherein theacoustic article comprises polyethylene, polypropylene, polyester,nylon, or a combination thereof.

Aspect 15A: The system of any one of the preceding aspects, wherein theacoustic article comprises a first layer and a second layer that iscoupled to the first layer, wherein the first layer is disposed betweenthe decorative element and the second layer.

Aspect 16A: The system of aspect 15A, wherein the first layer comprisesa woven material, wherein the second layer comprises a nonwovenmaterial, wherein the nonwoven material and woven material areintegrally formed as a composite material.

Aspect 17A: The system of aspect 15A or aspect 16A, further comprisingan adhesive disposed between the first layer and the decorative element.

Aspect 18A: The system of any one of the preceding aspects, furthercomprising a barrier between the acoustic article and the decorativeelement, wherein the barrier is liquid impermeable and/or breathable.

Aspect 19A: The system of aspect 18A, further comprising a levelingmaterial disposed between the barrier and the decorative element.

Aspect 20A: The system of any one of the preceding aspects, wherein thesystem is configured to achieve a High-frequency Impact Insulation Class(HIIC) rating of at least 65 in a lab test on a 6″ concrete floor withno ceiling.

Aspect 21A: The system of aspect 20A, wherein the system is configuredto achieve an HIIC rating of at least 68.

Aspect 22A: The system of any one of the preceding aspects, wherein thesystem is configured to achieve an Impact Insulation Class (IIC) ratingof at least 58 in a lab test on a 6″ concrete floor with no ceiling.

Aspect 23A: The system of any one of the preceding aspects, wherein theacoustic article has a density of at least 4.5 pounds per cubic foot.

Aspect 24A: The system of any one of the preceding aspects, wherein theacoustic article is compressible by 25% of the thickness when subject toa pressure from 2.1 lbf/in² to 20 lbf/in².

Aspect 25A: The system of any one of the preceding aspects, wherein theacoustic article is compressible by less than 15% when subject to apressure of 2 lbf/in².

Aspect 26A: The system of any one of the preceding aspects, wherein theacoustic article is compressible by between 10% and 25% of the thicknesswhen subject to a pressure of 2 lbf/in².

Aspect 27A: The system of aspect 1, wherein the acoustic article isdisposed on the opposing second side of the decorative element.

Aspect 28A: A method of installing the system as in any one of thepreceding aspects.

Aspect 29A: The method of aspect 28A, wherein the method comprisesplacing an assembly comprising the decorative element coupled to theacoustic article on a subfloor surface.

Aspect 30A: The method of aspect 28A, wherein the method comprises:

-   -   placing the acoustic article on a subfloor surface; and    -   placing the decorative element on the acoustic article.

Aspect 31A: The method of aspect 30A, further comprising depositing anadhesive between the acoustic article and the decorative element.

Aspect 32A: A decorative unit comprising:

-   -   a decorative element having a first side and an opposing second        side;    -   an acoustic article coupled to the decorative element on the        opposing second side of the decorative element, wherein the        acoustic article:        -   comprises an entangled fiber structure;        -   has a thickness of at least 0.4 mm; and        -   is compressible by less than 25% of the thickness when            subject to a pressure of 2 lbf/in².

Aspect 33A: The decorative unit of aspect 32A, wherein the decorativeelement comprises polymer.

Aspect 34A: The decorative unit of aspect 32A, wherein the decorativeelement comprises wood.

Aspect 35A: The decorative unit of any one of aspects 32A-34A, whereinthe decorative element is flexible and resilient.

Aspect 36A: The decorative unit of any one of aspects 32A-35A, whereinthe acoustic article has no filler dispersed therethrough.

Aspect 37A: The decorative unit of aspect 36A, wherein the acousticarticle consists essentially of nonwoven material and air dispersedtherethrough.

Aspect 38A: The decorative unit of any one of aspects 31A-37A, whereinacoustic article comprises a plurality of fibers having a denier above12.

Aspect 39A: The decorative unit of aspect 38A, wherein the denier isabout 15.

Aspect 40A: The decorative unit of any one of aspects 31A-39A, whereinthe acoustic article has a thickness from 0.7 mm to 25 mm.

Aspect 41A: The decorative unit of any one of aspects 31A-40A, whereinthe acoustic article comprises a first plurality of fibers having afirst melting point and a second plurality of fibers having a secondmelting point that is greater than the melting point of the firstplurality of fibers.

Aspect 42A: The decorative unit of any one of aspects 31A-41A, whereinthe acoustic article comprises a plurality of layers.

Aspect 43A: The decorative unit of aspect 42A, wherein the plurality oflayers have different respective densities.

Aspect 44A: The decorative unit of any one of aspects 31A-43A, whereinthe acoustic article comprises polyethylene, polypropylene, polyester,nylon, or a combination thereof.

Aspect 45A: The decorative unit of any one of aspects 31A-44A, whereinthe acoustic article comprises a first layer and a second layer that iscoupled to the first layer, wherein the first layer is disposed betweenthe decorative element and the second layer.

Aspect 46A: The decorative unit of aspect 45A, wherein the first layercomprises a woven material, wherein the second layer comprises anonwoven material, wherein the nonwoven material and woven material areintegrally formed as a composite material.

Aspect 47A: The decorative unit of aspect 45A or aspect 46A, furthercomprising an adhesive disposed between the first layer and thedecorative element.

Aspect 48A: The decorative unit of any one of aspects 31A-47, furthercomprising a barrier between the acoustic article and the decorativeelement, wherein the barrier is liquid impermeable and/or breathable.

Aspect 49A: The decorative unit of aspect 48A, further comprising aleveling material disposed between the barrier and the decorativeelement.

Aspect 50A: The decorative unit of any one of aspects 31A-49A, whereinthe system is configured to achieve a High-frequency Impact InsulationClass (HIIC) rating of at least 65 in a lab test on a 6″ concrete floorwith no ceiling.

Aspect 51A: The decorative unit of aspect 50A, wherein the system isconfigured to achieve an HIIC rating of at least 68 in a lab test on a6″ concrete floor with no ceiling.

Aspect 52A: The decorative unit of any one of aspects 31A-51A, whereinthe system is configured to achieve an Impact Insulation Class (IIC)rating of at least 58 in a lab test on a 6″ concrete floor with noceiling.

Aspect 53A: The decorative unit of any one of aspects 31A-52A, whereinthe acoustic article has a density of at least 4.5 pounds per cubicfoot.

Aspect 54A: The decorative unit of any one of aspects 31A-53A, whereinthe acoustic article is compressible by 25% of the thickness whensubject to a pressure from 2.1 lbf/in² to 10 lbf/in².

Aspect 55A: The decorative unit of any one of aspects 31A-54A, whereinthe acoustic article is compressible by less than 15% when subject to apressure of 2 lbf/in².

Aspect 56A: The decorative unit of any one of aspects 31A-55A, whereinthe acoustic article is compressible by between 10% and 25% of thethickness when subject to a pressure of 2 lbf/in².

Aspect 57A: The system of any one of aspects 1A-26A, wherein thedecorative element comprises a decorative portion and a substrate.

Aspect 58A: The system of aspect 57A, wherein the substrate of thedecorative element comprises a plurality of layers.

Aspect 59A: The system of aspect 58A, wherein the plurality of layerscomprise at least a first layer, a second layer, and a third layer,wherein the second layer is disposed between the first and third layers.

Aspect 60A: The system of aspect 59A, wherein the second layer isbreathable.

Aspect 61A: The system of aspect 60A, wherein the first and third layerscomprise at least one composite material or at least one engineeredhardwood material.

Aspect 62A: A decorative element comprising:

-   -   a decorative portion; and    -   a substrate comprising at least a first layer, a second layer,        and a third layer, wherein the second layer is disposed between        the first and third layers, wherein the second layer is a        breathable material.

Aspect 63A: The decorative element of aspect 62A, wherein the first andthird layers comprise at least one composite material or at least oneengineered hardwood material.

‘B’ Aspects

Aspect 1B: A system comprising:

-   -   a hard surface flooring material having a first side and an        opposing second side; and    -   a base pad disposed on the opposing second side of the hard        surface flooring material, wherein the base pad:        -   comprises a woven material, a non-woven material, or a            combination thereof;        -   has a thickness of at least 0.4 mm; and        -   is compressible by less than 25% of the thickness when            subjected to a pressure of 2 lbf/in².

Aspect 2B: The system of aspect 1B, wherein the hard surface flooringmaterial comprises polymer.

Aspect 3B: The system of aspect 1B, wherein the hard surface flooringmaterial comprises wood.

Aspect 4B: The system of aspect 1B, wherein the hard surface flooringmaterial comprises cementitious panel subfloor.

Aspect 5B: The system of any one of the preceding ‘B’ aspects, whereinthe hard surface flooring material is flexible and resilient.

Aspect 6B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad has no filler dispersed therethrough.

Aspect 7B: The system of aspect 6B, wherein the base pad consistsessentially of nonwoven material and air dispersed therethrough.

Aspect 8B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad comprises a plurality of fibers having a denier above 12.

Aspect 9B: The system of aspect 8B, wherein the denier is about 15.

Aspect 10B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad has a thickness from 0.4 mm to 25 mm.

Aspect 11B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad comprises a first plurality of fibers having a firstmelting point and a second plurality of fibers having a second meltingpoint that is greater than the melting point of the first plurality offibers.

Aspect 12B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad comprises a plurality of layers.

Aspect 13B: The system of aspect 12B, wherein the plurality of layershave different respective densities.

Aspect 14B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad comprises polyethylene, polypropylene, polyester, nylon, ora combination thereof.

Aspect 15B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad comprises a first layer and a second layer that is coupledto the first layer, wherein the first layer is disposed between the hardsurface flooring material and the second layer.

Aspect 16B: The system of aspect 15B, wherein the first layer comprisesa woven material, wherein the second layer comprises a nonwovenmaterial, wherein the nonwoven material and woven material areintegrally formed as a composite material.

Aspect 17B: The system of aspect 15B or aspect 16B, further comprisingan adhesive disposed between the first layer and the hard surfaceflooring material.

Aspect 18B: The system of any one of the preceding ‘B’ aspects, furthercomprising a barrier between the base pad and the hard surface flooringmaterial, wherein the barrier is liquid impermeable and/or breathable.

Aspect 19B: The system of aspect 18B, further comprising a levelingmaterial disposed between the barrier and the hard surface flooringmaterial.

Aspect 20B: The system of any one of the preceding ‘B’ aspects, whereinthe system is configured to achieve a High-frequency Impact InsulationClass (HIIC) rating of at least 65 in a lab test on a 6″ concrete floorwith no ceiling.

Aspect 21B: The system of aspect 20B, wherein the system is configuredto achieve an HIIC rating of at least 68.

Aspect 22B: The system of any one of the preceding ‘B’ aspects, whereinthe system is configured to achieve an Impact Insulation Class (IIC)rating of at least 58 in a lab test on a 6″ concrete floor with noceiling.

Aspect 23B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad has a density of at least 4.5 pounds per cubic foot.

Aspect 24B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad is compressible by 25% of the thickness when subject to apressure from 2.1 lbf/in² to 20 lbf/in².

Aspect 25B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad is compressible by less than 15% when subject to a pressureof 2 lbf/in².

Aspect 26B: The system of any one of the preceding ‘B’ aspects, whereinthe base pad is compressible by between 10% and 25% of the thicknesswhen subject to a pressure of 2 lbf/in².

Aspect 27B: A method of installing the system as in any one of thepreceding ‘B’ aspects.

Aspect 28B: The method of aspect 27B, wherein the method comprisesplacing an assembly comprising the hard surface flooring materialcoupled to the base pad on a subfloor surface.

Aspect 29B: The method of aspect 27B, wherein the method comprises:

-   -   placing the base pad on a subfloor surface; and    -   placing the hard surface flooring material on the base pad.

Aspect 30B: The method of aspect 29B, further comprising depositing anadhesive between the base pad and the hard surface flooring material.

Aspect 31B: A flooring element comprising:

-   -   a hard surface flooring material having a first side and an        opposing second side;    -   a base pad coupled to the hard surface flooring material on the        opposing second side of the hard surface flooring material,        wherein the base pad:        -   comprises a woven material, a nonwoven material, or a            combination thereof;        -   has a thickness of at least 0.4 mm; and        -   is compressible by less than 25% of the thickness when            subject to a pressure of 2 lbf/in².

Aspect 32B: The flooring element of aspect 31B, wherein the hard surfaceflooring material comprises polymer.

Aspect 33B: The flooring element of aspect 31B, wherein the hard surfaceflooring material comprises wood.

Aspect 34B: The flooring element of any one of aspects 31B-33B, whereinthe hard surface flooring material is flexible and resilient.

Aspect 35B: The flooring element of any one of aspects 31B-34B, whereinthe base pad has no filler dispersed therethrough.

Aspect 36B: The flooring element of aspect 35B, wherein the base padconsists essentially of nonwoven material and air dispersedtherethrough.

Aspect 37B: The flooring element of any one of aspects 31B-36B, whereinbase pad comprises a plurality of fibers having a denier above 12.

Aspect 38B: The flooring element of aspect 37B, wherein the denier isabout 15.

Aspect 39B: The flooring element of any one of aspects 31B-38B, whereinthe base pad has a thickness from 0.7 mm to 25 mm.

Aspect 40B: The flooring element of any one of aspects 31B-39B, whereinthe base pad comprises a first plurality of fibers having a firstmelting point and a second plurality of fibers having a second meltingpoint that is greater than the melting point of the first plurality offibers.

Aspect 41B: The flooring element of any one of aspects 31B-40B, whereinthe base pad comprises a plurality of layers.

Aspect 42B: The flooring element of aspect 41B, wherein the plurality oflayers have different respective densities.

Aspect 43B: The flooring element of any one of aspects 31B-42B, whereinthe base pad comprises polyethylene, polypropylene, polyester, nylon, ora combination thereof.

Aspect 44B: The flooring element of any one of aspects 31B-43B, whereinthe base pad comprises a first layer and a second layer that is coupledto the first layer, wherein the first layer is disposed between the hardsurface flooring material and the second layer.

Aspect 45B: The flooring element of aspect 44B, wherein the first layercomprises a woven material, wherein the second layer comprises anonwoven material, wherein the nonwoven material and woven material areintegrally formed as a composite material.

Aspect 46B: The flooring element of aspect 44B or aspect 45B, furthercomprising an adhesive disposed between the first layer and the hardsurface flooring material.

Aspect 47B: The flooring element of any one of aspects 31B-46B, furthercomprising a barrier between the base pad and the hard surface flooringmaterial, wherein the barrier is liquid impermeable and/or breathable.

Aspect 48B: The flooring element of aspect 47B, further comprising aleveling material disposed between the barrier and the hard surfaceflooring material.

Aspect 49B: The flooring element of any one of aspects 31B-48B, whereinthe system is configured to achieve a High-frequency Impact InsulationClass (HIIC) rating of at least 65 in a lab test on a 6″ concrete floorwith no ceiling.

Aspect 50B: The flooring element of aspect 49B, wherein the system isconfigured to achieve an HIIC rating of at least 68 in a lab test on a6″ concrete floor with no ceiling.

Aspect 51B: The flooring element of any one of aspects 31B-50B, whereinthe system is configured to achieve an Impact Insulation Class (IIC)rating of at least 58 in a lab test on a 6″ concrete floor with noceiling.

Aspect 52B: The flooring element of any one of aspects 31B-51B, whereinthe base pad has a density of at least 4.5 pounds per cubic foot.

Aspect 53B: The flooring element of any one of aspects 31B-52B, whereinthe base pad is compressible by 25% of the thickness when subject to apressure from 2.1 lbf/in² to 10 lbf/in².

Aspect 54B: The flooring element of any one of aspects 31B-53B, whereinthe base pad is compressible by less than 15% when subject to a pressureof 2 lbf/in².

Aspect 55B: The flooring element of any one of aspects 31B-54B, whereinthe base pad is compressible by between 10% and 25% of the thicknesswhen subject to a pressure of 2 lbf/in².

Aspect 56B The system of any one of aspects 1B-26B, wherein the hardsurface flooring material comprises a decorative portion and asubstrate.

Aspect 57B: The system of aspect 56B, wherein the substrate of the hardsurface flooring material comprises a plurality of layers.

Aspect 58B: The system of aspect 57B, wherein the plurality of layerscomprise at least a first layer, a second layer, and a third layer,wherein the second layer is disposed between the first and third layers.

Aspect 59B: The system of aspect 58B, wherein the second layer isbreathable.

Aspect 60B: The system of aspect 59B, wherein the first and third layerscomprise at least one composite material or at least one engineeredhardwood material.

Aspect 61B: A hard surface flooring material comprising:

-   -   a decorative portion; and    -   a substrate comprising at least a first layer, a second layer,        and a third layer, wherein the second layer is disposed between        the first and third layers, wherein the second layer is        breathable.

Aspect 62B: The hard surface flooring material of aspect 61B, whereinthe first and third layers comprise at least one composite material orat least one engineered hardwood material.

‘C’ Aspects

Aspect 1C: A system comprising:

-   -   a decorative element having a first side and an opposing second        side, wherein the decorative element has a first surface on the        first side and a second surface on the opposing second side;    -   an acoustic article disposed on the opposing second side of the        decorative element, wherein the acoustic article:        -   comprises a resiliently compressible material;        -   has a thickness of at least 0.4 mm; and        -   is compressible by less than 25% of the thickness when            subjected to a pressure of 2 lbf/in²; and    -   a stiffening structure between the decorative element and the        acoustic article.

Aspect 2C: The system of aspect 1C, wherein the stiffening structureconsists of a single layer.

Aspect 3C: The system of aspect 1C, wherein the stiffening structurecomprises a plurality of layers.

Aspect 4C: The system of aspect 3C, wherein the plurality of layers arelaminated together.

Aspect 5C: The system of aspect 4C, wherein the plurality of layerscomprise a layer of thermoplastic and a structural stabilizer.

Aspect 6C: The system of aspect 4C, wherein the plurality of layerscomprise two thermoplastic layers.

Aspect 7C: The system of aspect 6C, wherein the plurality of layersfurther comprise a structural stabilizer laminated between the twothermoplastic layers.

Aspect 8C: The system of any one of aspects 1C-3C, wherein thestiffening structure comprises a rigid fabric.

Aspect 9C: The system of any one of aspects 1C-3C, wherein thestiffening structure comprises a membrane.

Aspect 10C: The system of any one of the preceding ‘C’ aspects, whereinthe stiffening structure is coupled to the acoustic article.

Aspect 11C: The system of aspect 10C, wherein the stiffening structureis adhesively coupled to the acoustic article.

Aspect 12C: The system of aspect 10C, wherein the stiffening structureis bonded to the acoustic article.

Aspect 13C: The system of any one of the preceding ‘C’ aspects, whereinthe decorative element is coupled to the stiffening structure.

Aspect 14C: The system of aspect 13C, wherein the decorative element isadhesively coupled to the stiffening structure.

Aspect 15C: The system of any one of aspects 1C-12C, wherein thedecorative element is not coupled to the stiffening structure.

Aspect 16C: The system of any one of the preceding ‘C’ aspects, whereinthe stiffening structure comprises a first plurality of fibers having afirst melting point, wherein the acoustic article comprises a secondplurality of fibers having a second melting point that is higher thanthe first melting point, wherein at least a portion of the firstplurality of fibers are melted to form the stiffening structure.

Aspect 17C: The system of any one of the preceding ‘C’ aspects, whereinthe resiliently compressible material of the acoustic article comprisesan entangled fiber structure.

Aspect 18C: The system of aspect 17C, wherein the entangled fiberstructure comprises a needle bonded fabric.

Aspect 19C: The system of any one of the preceding ‘C’ aspects, whereinthe resiliently compressible material of the acoustic article comprisesfoam, rubber, or composite.

Aspect 20C: The system of any one of the preceding ‘C’ aspects, whereinthe stiffening structure and the acoustic article have respectivematerial properties such that the stiffening structure and the acousticarticle cooperate to provide a stiffness of at least 40,000microjoules/meter when measured in accordance with ASTM D1388-18.

Aspect 21C: The system of any one of the preceding ‘C’ aspects, whereinthe stiffening structure and the acoustic article have respectivematerial properties such that the stiffening structure and the acousticarticle cooperate to provide a stiffness of at least 100,000microjoules/meter when measured in accordance with ASTM D1388-18.

Aspect 22C: The system of any one of the preceding ‘C’ aspects, whereinthe stiffening structure and the acoustic article have respectivematerial properties such that the stiffening structure and the acousticarticle cooperate to provide a stiffness of 2 times a stiffness of theacoustic article alone, when measured in accordance with ASTM D1388-18.

Aspect 23C: The system of any one of aspects 1C-22C, wherein thedecorative element comprises polymer.

Aspect 24C: The system of any one of aspects 1C-22C, wherein thedecorative element comprises wood.

Aspect 25C: The system of any one of aspects 1C-22C, wherein thedecorative element comprises cementitious panel subfloor.

Aspect 26C: The system of any one of the preceding ‘C’ aspects, whereinthe decorative element is flexible and resilient.

Aspect 27C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article has no filler dispersed therethrough.

Aspect 28C: The system of aspect 27C, wherein the acoustic articleconsists essentially of nonwoven material and air dispersedtherethrough.

Aspect 29C: The system of aspect any one of the preceding ‘C’ aspects,wherein the acoustic article comprises a plurality of fibers having adenier above 12.

Aspect 30C: The system of aspect 29C, wherein the denier is about 15.

Aspect 31C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article has a thickness from 0.4 mm to 25 mm.

Aspect 32C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article comprises a first plurality of fibers having afirst melting point and a second plurality of fibers having a secondmelting point that is greater than the melting point of the firstplurality of fibers.

Aspect 33C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article comprises a plurality of layers.

Aspect 34C: The system of aspect 33C, wherein the plurality of layershave different respective densities.

Aspect 35C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article comprises polyethylene, polypropylene, polyester,nylon, or a combination thereof.

Aspect 36C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article comprises a first layer and a second layer that iscoupled to the first layer, wherein the first layer is disposed betweenthe decorative element and the second layer.

Aspect 37C: The system of aspect 36C, wherein the first layer comprisesa woven material, wherein the second layer comprises a nonwovenmaterial, wherein the nonwoven material and woven material areintegrally formed as a composite material.

Aspect 38C: The system of aspect 37C, further comprising an adhesivedisposed between the first layer and the decorative element.

Aspect 39C: The system of any one of the preceding ‘C’ aspects, furthercomprising a barrier between the acoustic article and the decorativeelement, wherein the barrier is liquid impermeable and/or breathable.

Aspect 40C: The system of aspect 39C, further comprising a levelingmaterial disposed between the barrier and the decorative element.

Aspect 41C: The system of any one of the preceding ‘C’ aspects, whereinthe system is configured to achieve a High-frequency Impact InsulationClass (HIIC) rating of at least 63 in a lab test on a 6″ concrete floorwith no ceiling.

Aspect 42C: The system of aspect 41C, wherein the system is configuredto achieve an HIIC rating of at least 64.

Aspect 43C: The system of any one of the preceding ‘C’ aspects, whereinthe system is configured to achieve an Impact Insulation Class (IIC)rating of at least 58 in a lab test on a 6″ concrete floor with noceiling.

Aspect 44C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article has a density of at least 4.5 pounds per cubicfoot.

Aspect 45C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article is compressible by 25% of the thickness whensubject to a pressure from 2.1 lbf/in² to 20 lbf/in².

Aspect 46C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article is compressible by less than 15% when subject to apressure of 2 lbf/in².

Aspect 47C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article is compressible by between 10% and 25% of thethickness when subject to a pressure of 2 lbf/in².

Aspect 48C: The system of any one of the preceding ‘C’ aspects, whereinthe acoustic article is disposed on the opposing second side of thedecorative element.

Aspect 49C: A method comprising:

installing the system as in any one of the preceding ‘C’ aspects onto asubfloor surface.

Aspect 50C: The method of aspect 49C, wherein the method comprisesplacing an assembly comprising the decorative element coupled to theacoustic article, with the stiffening structure disposed between thedecorative element and the acoustic article, on the subfloor surface.

Aspect 51C: The method of aspect 49C, wherein the method comprises:

-   -   placing the acoustic article, with the stiffening structure        coupled thereto, on the subfloor surface; and    -   placing the decorative element on the stiffening structure.

Aspect 52C: The method of aspect 51C, further comprising depositing anadhesive between the stiffening structure and the decorative element.

Aspect 53C: A decorative unit comprising:

-   -   a decorative element having a first side and an opposing second        side, wherein the decorative element has a first surface on the        first side and a second surface on the opposing second side;    -   an acoustic article coupled to the decorative element on the        opposing second side of the decorative element, wherein the        acoustic article:        -   comprises a resiliently compressible material;        -   has a thickness of at least 0.4 mm; and        -   is compressible by less than 25% of the thickness when            subject to a pressure of 2 lbf/in²; and    -   a stiffening structure between the decorative element and the        acoustic article.

Aspect 54C: The decorative unit of aspect 53C, wherein the decorativeelement comprises polymer.

Aspect 55C: The decorative unit of aspect 53C, wherein the decorativeelement comprises wood.

Aspect 56C: The decorative unit of aspect 53C, wherein the decorativeelement is flexible and resilient.

Aspect 57C: The decorative unit of aspect 53C, wherein the acousticarticle has no filler dispersed therethrough.

Aspect 58C: The decorative unit of aspect 57C, wherein the acousticarticle consists essentially of nonwoven material and air dispersedtherethrough.

Aspect 59C: The decorative unit of aspect 53C, wherein acoustic articlecomprises a plurality of fibers having a denier above 12.

Aspect 60C: The decorative unit of aspect 59C, wherein the denier isabout 15.

Aspect 61C: The decorative unit of aspect 53C, wherein the acousticarticle has a thickness from 0.7 mm to 25 mm.

Aspect 62C: The decorative unit of aspect 53C, wherein the acousticarticle comprises a first plurality of fibers having a first meltingpoint and a second plurality of fibers having a second melting pointthat is greater than the melting point of the first plurality of fibers.

Aspect 63C: The decorative unit of aspect 53C, wherein the acousticarticle comprises a plurality of layers.

Aspect 64C: The decorative unit of aspect 53C, wherein the plurality oflayers have different respective densities.

Aspect 65C: The decorative unit of aspect 53C, wherein the acousticarticle comprises polyethylene, polypropylene, polyester, nylon, or acombination thereof.

Aspect 66C: The decorative unit of aspect 53C, wherein the acousticarticle comprises a first layer and a second layer that is coupled tothe first layer, wherein the first layer is disposed between thedecorative element and the second layer.

Aspect 67C: The decorative unit of aspect 66C, wherein the first layercomprises a woven material, wherein the second layer comprises anonwoven material, wherein the nonwoven material and woven material areintegrally formed as a composite material.

Aspect 68C: The decorative unit of aspect 66C, further comprising anadhesive disposed between the first layer and the decorative element.

Aspect 69C: The decorative unit of aspect 68C, further comprising abarrier between the acoustic article and the decorative element, whereinthe barrier is liquid impermeable and/or breathable.

Aspect 70C: The decorative unit of aspect 69C, further comprising aleveling material disposed between the barrier and the decorativeelement.

Aspect 71C: The decorative unit of aspect 53C, wherein the system isconfigured to achieve a High-frequency Impact Insulation Class (HIIC)rating of at least 63 in a lab test on a 6″ concrete floor with noceiling.

Aspect 72C: The decorative unit of aspect 71C, wherein the system isconfigured to achieve an HIIC rating of at least 64 in a lab test on a6″ concrete floor with no ceiling.

Aspect 73C: The decorative unit of aspect 53C, wherein the system isconfigured to achieve an Impact Insulation Class (IIC) rating of atleast 58 in a lab test on a 6″ concrete floor with no ceiling.

Aspect 74C: The decorative unit of aspect 53C, wherein the acousticarticle has a density of at least 4.5 pounds per cubic foot.

Aspect 75C: The decorative unit of aspect 53C, wherein the acousticarticle is compressible by 25% of the thickness when subject to apressure from 2.1 lbf/in² to 10 lbf/in².

Aspect 76C: The decorative unit of aspect 51C, wherein the acousticarticle is compressible by less than 15% when subject to a pressure of 2lbf/in².

Aspect 77C: The decorative unit of aspect 53C, wherein the acousticarticle is compressible by between 10% and 25% of the thickness whensubject to a pressure of 2 lbf/in².

Aspect 78C: A subsurface article comprising:

-   -   an acoustic article comprising a resiliently compressible        material, wherein the acoustic article:        -   has a thickness of at least 0.4 mm; and        -   is compressible by less than 25% of the thickness when            subjected to a pressure of 2 lbf/in²,    -   wherein the acoustic article has a first side; and    -   a stiffening structure positioned on the first side of the        acoustic article.

Aspect 79C: The subsurface article of aspect 78C, wherein the stiffeningstructure consists of a single layer.

Aspect 80C: The subsurface article of aspect 78C, wherein the stiffeningstructure comprises a plurality of layers.

Aspect 81C: The subsurface article of aspect 80C, wherein the pluralityof layers are laminated together.

Aspect 82C: The subsurface article of aspect 81C, wherein the pluralityof layers comprise a layer of thermoplastic and a structural stabilizer.

Aspect 83C: The subsurface article of aspect 81C, wherein the pluralityof layers comprise two thermoplastic layers.

Aspect 84C: The subsurface article of aspect 83C, wherein the pluralityof layers further comprise a structural stabilizer laminated between thetwo thermoplastic layers.

Aspect 85C: The subsurface article of any one of aspects 78C-80C,wherein the stiffening structure comprises a rigid fabric.

Aspect 86C: The subsurface article of any one of aspects 78C-80C,wherein the stiffening structure comprises a membrane.

Aspect 87C: The subsurface article of any one of aspects 78C-86C,wherein the stiffening structure is coupled to the acoustic article.

Aspect 88C: The subsurface article of aspect 87C, wherein the stiffeningstructure is adhesively coupled to the acoustic article.

Aspect 89C: The subsurface article of aspect 87C, wherein the stiffeningstructure is bonded to the acoustic article.

Aspect 90C: The subsurface article of any one of aspects 78C-89C,wherein the stiffening structure comprises a first plurality of fibershaving a first melting point, wherein the acoustic article comprises asecond plurality of fibers having a second melting point that is higherthan the first melting point, wherein at least a portion of the firstplurality of fibers are melted to form the stiffening structure.

Aspect 91C: The subsurface article of any one of aspects 78C-90C,wherein the resiliently compressible material of the acoustic articlecomprises an entangled fiber structure.

Aspect 92C: The subsurface article of aspect 91C, wherein the entangledfiber structure comprises a needle bonded fabric.

Aspect 93C: The subsurface article of any one of aspects 78C-92C,wherein the resiliently compressible material of the acoustic articlecomprises foam, rubber, or composite.

Aspect 94C: The subsurface article of any one of aspects 78C-93C,wherein the stiffening structure and the acoustic article haverespective material properties such that the stiffening structure andthe acoustic article cooperate to provide a stiffness of at least 40,000microjoules/meter when measured in accordance with ASTM D1388-18.

Aspect 95C: The subsurface article of any one of aspects 78C-94C,wherein the stiffening structure and the acoustic article haverespective material properties such that the stiffening structure andthe acoustic article cooperate to provide a stiffness of at least1000,000 microjoules/meter when measured in accordance with ASTMD1388-18.

Aspect 96C: The subsurface article of any one of aspects 78C-95C,wherein the stiffening structure and the acoustic article haverespective material properties such that the stiffening structure andthe acoustic article cooperate to provide a stiffness of 2 times astiffness of the acoustic article alone, when measured in accordancewith ASTM D1388-18.

Although the foregoing invention has been described in some detail byway of illustration and example for purposes of clarity ofunderstanding, certain changes and modifications may be practiced withinthe scope of the appended claims.

What is claimed is:
 1. A system comprising: a decorative element havinga first side and an opposing second side, wherein the decorative elementhas a first surface on the first side and a second surface on theopposing second side; an acoustic article disposed on the opposingsecond side of the decorative element, wherein the acoustic article:comprises a resiliently compressible material; has a thickness of atleast 0.4 mm; and is compressible by less than 25% of the thickness whensubjected to a pressure of 2 lbf/in²; and a stiffening structure betweenthe decorative element and the acoustic article.
 2. The system of claim1, wherein the stiffening structure consists of a single layer.
 3. Thesystem of claim 1, wherein the stiffening structure comprises aplurality of layers.
 4. The system of claim 3, wherein the plurality oflayers are laminated together.
 5. The system of claim 4, wherein theplurality of layers comprise a layer of thermoplastic and a structuralstabilizer.
 6. The system of claim 4, wherein the plurality of layerscomprise two thermoplastic layers.
 7. The system of claim 6, wherein theplurality of layers further comprise a structural stabilizer laminatedbetween the two thermoplastic layers.
 8. The system of claim 1, whereinthe stiffening structure and the acoustic article have respectivematerial properties such that the stiffening structure and the acousticarticle cooperate to provide a stiffness of at least 40,000microjoules/meter when measured in accordance with ASTM D1388-18.
 9. Thesystem of claim 1, wherein the stiffening structure and the acousticarticle have respective material properties such that the stiffeningstructure and the acoustic article cooperate to provide a stiffness ofat least 100,000 microjoules/meter when measured in accordance with ASTMD1388-18.
 10. The system of claim 1, wherein the stiffening structureand the acoustic article have respective material properties such thatthe stiffening structure and the acoustic article cooperate to provide astiffness of 2 times a stiffness of the acoustic article alone, whenmeasured in accordance with ASTM D1388-18.
 11. A decorative unitcomprising: a decorative element having a first side and an opposingsecond side, wherein the decorative element has a first surface on thefirst side and a second surface on the opposing second side; an acousticarticle coupled to the decorative element on the opposing second side ofthe decorative element, wherein the acoustic article: comprises aresiliently compressible material; has a thickness of at least 0.4 mm;and is compressible by less than 25% of the thickness when subject to apressure of 2 lbf/in²; and a stiffening structure between the decorativeelement and the acoustic article.
 12. A subsurface article comprising:an acoustic article comprising a resiliently compressible material,wherein the acoustic article: has a thickness of at least 0.4 mm; and iscompressible by less than 25% of the thickness when subjected to apressure of 2 lbf/in², wherein the acoustic article has a first side;and a stiffening structure positioned on the first side of the acousticarticle, wherein the stiffening structure and the acoustic article haverespective material properties such that the stiffening structure andthe acoustic article cooperate to provide a stiffness of at least 40,000microjoules/meter when measured in accordance with ASTM D1388-18. 13.The subsurface article of claim 12, wherein the stiffening structureconsists of a single layer.
 14. The subsurface article of claim 12,wherein the stiffening structure comprises a plurality of layers. 15.The subsurface article of claim 14, wherein the plurality of layers arelaminated together.
 16. The subsurface article of claim 14, wherein theplurality of layers comprise a layer of thermoplastic and a structuralstabilizer.
 17. The subsurface article of claim 14, wherein theplurality of layers comprise two thermoplastic layers.
 18. Thesubsurface article of claim 14, wherein the plurality of layers furthercomprise a structural stabilizer laminated between the two thermoplasticlayers.
 19. The subsurface article of claim 12, wherein the stiffeningstructure and the acoustic article have respective material propertiessuch that the stiffening structure and the acoustic article cooperate toprovide a stiffness of at least 1000,000 microjoules/meter when measuredin accordance with ASTM D1388-18.
 20. The subsurface article of claim12, wherein the stiffening structure and the acoustic article haverespective material properties such that the stiffening structure andthe acoustic article cooperate to provide a stiffness of 2 times astiffness of the acoustic article alone, when measured in accordancewith ASTM D1388-18.